Commercial

Airplanes 737

Service Bulletin

ALERT

Number: 737-28A1212

Original Issue: July 23, 2009

Revision 2: October 18, 2012

ATA System: 2822

SUBJECT: FUEL - Engine Fuel Feed System - Fuel Pump Control Ground Fault Interrupter (GFI)

Relay Installation

Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15

CFR 300-774). An export license may be required before it is used for development, production or use by foreign

persons from specific countries. The controller of this data has the individual responsibility to abide by all export

laws.

ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET

Copyright © 2009 Boeing.

Unpublished Work. All Rights Reserved.

Treatment of this document and its content is governed by contract with Boeing. Rights to use this document

are licensed on a per aircraft basis and such rights may not be transferable. For more information, contact The

Boeing Company.

Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, DreamlinerTM,

BBJ, DC-8, DC-9, DC-10, KC-10, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8A, Poseidon and Boeing

liveries are all trademarks owned by The Boeing Company; and no trademark license is granted in connection

with this document unless provided in writing by Boeing. BOEING is a trademark of Boeing Management

Company.

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Revision 2: October 18, 2012 737-28A1212

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2.0
Export Controlled ECCN: 9E991 - BOEING

PROPRIETARY - Copyright © Unpublished

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Revision 2: October 18, 2012 737-28A1212

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BOEING SERVICE BULLETIN 737-28A1212

ALERT ALERT

BLANK PAGE
Table of Contents

Revision Transmittal Sheet ............................................ 5

Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

1. PLANNING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

A. Effectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

1. Airplanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

E. Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

2. Data Supplied with this Service Bulletin: . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

3. Installation Drawings Used in the Preparation of this Service Bulletin: . . . . . . . . . . . 42

K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

M. Software Accomplishment Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

A. Material - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

C. Parts Necessary for Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

1. Kits/Parts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

2. Parts and Materials Supplied by the Operator: . . . . . . . . . . . . . . . . . . . . . . . . 49

3. Parts Modified and Reidentified: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

4. Parts Removed and Not Replaced: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

E. Special Tooling - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . . . 52

3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

FIGURE 1: M181, M182, M183 RELAY MODULE ASSEMBLY - REPLACEMENT [Group 1, 8] . . . . 58

FIGURE 2: P6-2 RELAY PANEL - FUEL PUMP POWER RELAY - REPLACEMENT [Group 2, Configuration

1] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

FIGURE 3: P6-2 RELAY PANEL - FUEL PUMP POWER RELAY - REPLACEMENT [Group 3, 10-13,

Configuration 1] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

FIGURE 4: P6-2 RELAY PANEL - FUEL PUMP POWER RELAY - REPLACEMENT [Group 4, Configuration

1] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

FIGURE 5: P6-2 RELAY PANEL - FUEL PUMP POWER RELAY - REPLACEMENT [Group 5, Configuration

1] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

FIGURE 6: P6-2 RELAY PANEL - FUEL PUMP POWER RELAY - REPLACEMENT [Group 6, Configuration

1] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Export Controlled ECCN: 9E991 - BOEING

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Revision 2: October 18, 2012 737-28A1212

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BOEING SERVICE BULLETIN 737-28A1212

ALERT ALERT
FIGURE 7: P6-2 RELAY PANEL - FUEL PUMP POWER RELAY - REPLACEMENT [Group 7, 9, Configuration

1] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

FIGURE 8: W0044 WIRE BUNDLE - LOCATION [Group 2-3, 6-7, 9-13, Configuration 1] . . . . . . . 82

FIGURE 9: WIRE BUNDLE W0044 - WIRING CHANGES [Group 2, Configuration 1] . . . . . . . . . 83

FIGURE 10: WIRE BUNDLE W0044 - WIRING CHANGES [Group 3, 12, Configuration 1] . . . . . . . 85

FIGURE 11: WIRE BUNDLE W0044 - WIRING CHANGES [Group 6-7, 9, Configuration 1] . . . . . . . 87

FIGURE 12: WIRE BUNDLE W0044 - WIRING CHANGES [Group 10, Configuration 1] . . . . . . . . . 88

FIGURE 13: WIRE BUNDLE W0044 - WIRING CHANGES [Group 11, 13, Configuration 1] . . . . . . . 89

FIGURE 14: FUEL BOOST PUMP CONNECTOR - WIRE LOCATION [Group 8] . . . . . . . . . . . . 91

FIGURE 15: FUEL BOOST PUMP GROUNDS - WIRE LOCATION [Group 8] . . . . . . . . . . . . . . 92

FIGURE 16: FUEL BOOST PUMP CONNECTOR - WIRING CHANGES [Group 8] . . . . . . . . . . . 93

FIGURE 17: FUEL BOOST PUMP CONNECTOR - WIRE LOCATION [Group 8] . . . . . . . . . . . . 94

FIGURE 18: FUEL BOOST PUMP GROUNDS - WIRE LOCATION [Group 8] . . . . . . . . . . . . . . 95

FIGURE 19: FUEL BOOST PUMP CONNECTOR - WIRING CHANGES [Group 8] . . . . . . . . . . . 96

FIGURE 20: FUEL BOOST PUMP CONTROL GROUND FAULT INTERRUPTER (GFI) CONTROL RELAY

- REFERENCE [Group 2-7, 9-13, Configuration 1] . . . . . . . . . . . . . . . . . . . . . . 97

FIGURE 21: WIRE BUNDLE W0044 - WIRING CHANGES [Group 1, 8] . . . . . . . . . . . . . . . . . 98

FIGURE 22: P6-2 RELAY PANEL - GROUND STUDS AND BONDING JUMPER - INSTALLATION [Group

2-4; Group 5, Configuration 1-2; Group 6, Configuration 1-2; Group 7, Configuration 1-2; Group

9, Configuration 1-2; Group 10-13] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

FIGURE 23: P6-2 RELAY PANEL - FUEL PUMP POWER GFI RELAY - TURN [Group 5, Configuration 2-3]

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

FIGURE 24: P6-2 RELAY PANEL - FUEL PUMP POWER GFI RELAY - TURN [Group 6, Configuration 2-3]

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

FIGURE 25: P6-2 RELAY PANEL - FUEL PUMP POWER GFI RELAY - TURN [Group 7, Configuration 2-3;

Group 9, Configuration 2-3] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

Appendix A: ELECTRICAL BONDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

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BOEING SERVICE BULLETIN 737-28A1212

ALERT ALERT
Commercial

Airplanes 737

Service Bulletin

ALERT

Revision Transmittal Sheet Number: 737-28A1212

Original Issue: July 23, 2009

Revision 2: October 18, 2012

ATA System: 2822

SUBJECT: FUEL - Engine Fuel Feed System - Fuel Pump Control Ground Fault Interrupter (GFI)

Relay Installation

This revision includes all pages of the service bulletin.

COMPLIANCE INFORMATION RELATED TO THIS REVISION

Federal Aviation Administration (FAA) Airworthiness Directive AD 2011-12-09 is related to this service bulletin.

More work is necessary for Group 5, 6, 7 and 9 airplanes that have been changed in accordance with the Original

Issue or Revision 1 of this service bulletin:-

– For airplanes that have incorporated the Original Issue of this service bulletin, but not Revision 1, it is

necessary to change the position of two Ground Fault Interrupt (GFI) relays, on the P6-2 relay panel, install

a bonding jumper between the P6-2 relay panel and P6 Load Control Center structure, do a bonding check

of the GFI relays and do a GFI operational test. This work is identified as Configuration 2 for these groups.

– For airplanes that have incorporated Revision 1 of this service bulletin, it is necessary to change the position

of two GFI relays on the P6-2 relay panel, do a bonding check and a GFI operational test, for related fuel

boost pumps. This work is identified as Configuration 3 for these groups.

More work is necessary for Group 2-4 and Group 10-13 airplanes that have been changed in accordance with

the Original Issue of this service bulletin. It is necessary to install a bonding jumper between the P6-2 relay panel

and P6 Load Control Center structure, then do a GFI operational test of the fuel boost pumps. This work is

identified as Configuration 2 for these groups.

No more work is necessary for Group 2-4 and Group 10-13 airplanes that have been changed in accordance

with Revision 1 of this service bulletin.

The Alternative Method Of Compliance (AMOC) to the requirements of paragraph (g), (h), (i), (j) and (k) of AD

2011-12-09, for Revision 2 of this bulletin, does not apply to Group 1 and 8 airplanes (line numbers 1 thru 291),

operators should contact the Boeing company for more instructions to do this change.

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REASON FOR REVISION

This revision is sent to update the installation of new GFI relays because the GFI system might not function

correctly after their installation on Groups 5, 6, 7 and 9 airplanes. Boeing received a report from one operator

that told of incorrect operation of new 9524G-10674 GFI relays. A subsequent investigation and test found that

Electromagnetic Interference (EMI), between the new 9524G-10674 relays and adjacent KCG-X4L-001 relays

could cause problems with the function of new relays and thus the operation of GFI system. The instructions

have therefore been updated to change the position of the GFI relays. Other groups are not affected by this

problem because of differences in the P6-2 relay panel layout. This revision is a final solution to the problem

described in 737-28A1212 IN 02 and requires no new parts to be supplied or kit changes. Operators of airplanes

in Groups 5, 6 and 7 can now continue to incorporate this service bulletin at this revision.

In addition, instructions to change airplane line numbers 1-291, in Groups 1 and 8, are removed. Operators with

these airplanes should contact The Boeing Company to get engineering and accomplishment instructions for

this change.

As a result of Boeing checks on the Group Configuration, the airplanes that follow are moved between groups

of the service bulletin effectivity.

1. Airplanes line numbers 263 thru 267 and 269 thru 291 are moved from Group 2 to Group 1.

2. Airplanes variable numbers PQ951, PR077-PR080 and PT681-PT685 are moved from Group 4 to

Group 5.

3. Airplanes variable numbers PW511-PW512 are moved from Group 6 to Group 7.

4. Airplane variable number PW702, and thus Group 9, is changed to be applicable to Figure 7 and not

Figure 3.

These sections are changed:

1. In Summary, Concurrent Requirements: Removed data for withdrawn Groups 1 and 8. Added none.

2. In Summary, Background: Added reference to Boeing Fleet Team Digest 737 FTD 28-04005 and

Boeing Service Letter 737-SL-28-070.

3. In Summary, Action: Added Part descriptions, new group configurations and Part 3 for withdrawn

Groups 1 and 8. Added more work in Parts 1, 2 and new Part 4. Added Part 1, Step 6.

4. In Summary, Compliance: Added FAA AD 2011-12-09. Added statement for withdrawn Groups 1 and

8. Updated statement for other groups based on more work required and revision.

5. In Summary, Illustration: Added more work for Configuration 2 and 3 and updated Configuration 1

description.

6. In Paragraph 1.A., Effectivity: Added Configuration 3 for Groups 5, 6, 7 and 9. Updated the Group

Configuration table descriptions. Corrected the Group of airplanes given above. Removed Configurations

for Groups 1 and 8.

7. In Paragraph 1.B., Concurrent Requirements: Removed data for withdrawn Groups 1 and 8. Added

none.

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BOEING SERVICE BULLETIN 737-28A1212

ALERT ALERT
8. In Paragraph 1.C., Reason: Added reference to Boeing Fleet Team Digest 737 FTD 28-04005 and

Boeing Service Letter 737-SL-28-070.

9. In Paragraph 1.D., Description: Added Part descriptions, new group configurations and Part 3 for

withdrawn Groups 1 and 8. Added more work in Parts 1, 2 and new Part 4. Added Part 1, Step 6.

10. In Paragraph 1.E., Compliance: Added FAA AD 2011-12-09. Added statement for withdrawn Groups

1 and 8. Updated statement for other groups based on more work required and revision.

11. In Paragraph 1.F., Approval: Added Alternative Method of Compliance statement with reference to

FAA Airworthiness Directive AD 2011-12-09.

12. In Paragraph 1.G., Manpower: Added Part descriptions, new group configurations and Part 3 for

withdrawn Groups 1 and 8. Added Figures and estimates for more work in Parts 1, 2 and new Part 4.

Changed Group 9 applicability.

13. In Paragraph 1.K., Publications Affected: Added Equipment List to Wiring Diagram Manual sections.

14. In Paragraph 1.I., Electrical Load Data: Added note for withdrawn Groups 1 and 8. Applied Group

Configurations. Corrected DC Load Table - added Group 13 and moved Group 9.

15. Added Paragraph 1.M., Software Accomplishment Summary: New service bulletin section - not affected.

16. In Paragraph 1.J., References: Updated to include items added at Revision 2 and not added at Revision

1.

17. In Paragraph 2.A., Material - Price and Availability: Updated tables and new Pricing and ROLT. Separated

tables for new group configurations and Kit applicability. Added note for withdrawn Groups 1 and 8.

18. In Paragraph 2.C.1., Kits/Parts: Added note for withdrawn Groups 1 and 8. Applied new group

configurations to tables. Added missing footnote (a) reference and note for Configuration 3.

19. In Paragraph 2.C.2., Parts and Materials Supplied by the Operator: Added note for withdrawn Groups

1 and 8 and removed related part numbers from tables. Added new table for consumable materials,

added at Revision 1. Separated part tables by Group / Configuration and added existing parts column,

with instructions. Changed parts applicable to Group 9.

20. In .Paragraph 2.C.3., Parts Modified and Reidentified: Added note for withdrawn Groups 1 and 8 and

removed related table. Added note for other groups.

21. In Paragraph 3.B., Work Instructions: Added note for withdrawn Groups 1 and 8.

22. In Paragraph 3.B., Work Instructions, Part 1: Updated title. Removed Groups 1 and 8 and renumbered

all steps. Moved Group 9 applicability. Added more work in Steps 10 thru 12. Corrected Steps 5, 18

and 21. Added Step 25.

23. In Paragraph 3.B., Work Instructions, Part 2: Updated title and Step 5. Added more work for Configuration

2, applicable to Groups 5-7 and 9 in Step 4. Added test detail in Step 6.

24. In Paragraph 3.B., Work Instructions, Part 3: Deleted - applicable to withdrawn Groups 1 and 8.

25. Added Paragraph 3.B., Work Instructions, Part 4: To give Configuration 3 work instructions for Groups

5-7 and 9.

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BOEING SERVICE BULLETIN 737-28A1212

ALERT ALERT
26. Figure 1: Deleted - applicable to withdrawn Groups 1 and 8.

27. In Figures 2, 3 and 4: Updated titles, Alodine naming and related more data and cleaning step quantity

to agree with other figures.

28. In Figure 3: Removed Group 9 applicability.

29. In Figures 5, 6 and 7: Changed Illustrations and Step Tables to add more work for Configuration 1 and

update formats. Added Steps 3, 4, 8, 9, 10 and 13 and footnotes (d) thru (i). Updated titles, cleaning

step quantity, Alodine naming and related more data.

30. In Figure 7: Added Group 9 applicability.

31. In Figure 8: Updated title.

32. Figures 14 thru 19: Deleted - applicable to withdrawn Group 8.

33. Figure 21: Deleted - applicable to withdrawn Groups 1 and 8.

34. In Figure 22: Updated title, Alodine naming, and Applicability. Corrected Sheet 3 illustration.

35. Added Figures 23, 24 and 25: To give more work for Groups 5-7 and 9, Configuration 2 and 3.

36. In Appendix A: Added titles for Figure 1 and Figure 2. Corrected Paragraphs 1.a.(3), 1.a.(4), 2.a.(4),

2.a.(7) and 5.a.(1).(a).

The data given in Information Notices 737-28A1212 IN 01 and 737-28A1212 IN 02 is included in this revision,

as applicable.

Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity, to show the location

of important changes.

Pages with no vertical lines have no important changes.

REVISION HISTORY

Original Issue: July 23, 2009

Revision 1: August 27, 2010

Revision 2: October 18, 2012

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BOEING SERVICE BULLETIN 737-28A1212

ALERT ALERT
Commercial

Airplanes 737

Service Bulletin

ALERT

Summary Number: 737-28A1212

Original Issue: July 23, 2009

Revision 2: October 18, 2012

ATA System: 2822

SUBJECT: FUEL - Engine Fuel Feed System - Fuel Pump Control Ground Fault Interrupter (GFI)

Relay Installation

THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH

1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO

THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO

THE NEW OWNER.

CONCURRENT REQUIREMENTS

None.

BACKGROUND

This service bulletin gives the instructions to replace the power control relays for the fuel boost pumps. The

relays are located in the P6 circuit breaker panel in the flight compartment. The new relays include a Ground

Fault Interrupt (GFI) feature. The GFI relay feature will protect the fuel pumps from damage caused by electrical

arcing because the electrical power will be removed from the pump if a ground fault is detected. Electrical arcing

could create a possible source of ignition of flammable fuel vapors in the fuel tanks. Ignition of flammable fuel

vapors could cause a fire or explosion which could put the airplane in an unsafe condition.

This service bulletin is the result of the safety assessments conducted by Boeing under SFAR 88, "Fuel Tank

System Fault Tolerance Evaluation Requirements".

This change affects section 9 of the Maintenance Planning Data (MPD) Document. The Airworthiness Limitations

(AWL) "28-AWL-23" (737-100/200/200C airplanes) and "28-AWL-22" (737-300/400/500 airplanes) are related

to this service bulletin.

Boeing Fleet Team Digest 737 FTD 28-04005 is related to this service bulletin.

Boeing Service Letter 737-SL-28-070 is related to this service bulletin.

ACTION (PRR 35440-10RS)

Group 2-7, 9-13, Configuration 1:

PART 1 - GROUND STUDS AND BONDING JUMPER INSTALLATION AND FUEL BOOST PUMP

RELAYS REPLACEMENT

1. Get access to the flight compartment.

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2. At the P6 Load Control Center install two ground studs and a ground bonding jumper.

3. Measure the electrical bonding between the P6-2 relay panel and P6 Load Control Center structure.

4. Replace relays on the P6-2 relay panel with new Ground Fault Interrupt (GFI) relays as follows:

a. Group 2, 4, Configuration 1:

Replace six relays.

b. Group 3, 10-13, Configuration 1:

Replace eight relays.

c. Group 5, Configuration 1:

Replace six relays, with R18 and R19 turned 180 degrees.

d. Group 6-7, 9, Configuration 1:

Replace eight relays, with R146 and R147 turned 180 degrees.

5. Measure the electrical bonding between each of the new GFI relays and the P6-2 relay panel and repair

the bond if necessary.

6. Group 2-3, 6-7, 9-13, Configuration 1:

Change the W0044 wire bundle.

7. Do a Ground Fault Interrupter (GFI) - Operational Test of the GFI relay installation for the fuel boost

pumps.

Group 2-7, 9-13, Configuration 2:

PART 2 - MORE WORK - GROUND STUDS AND BONDING JUMPER INSTALLATION AND GFI RELAY

POSITION CHANGE

1. Get access to the flight compartment.

2. At the P6 Load Control Center install two ground studs and a ground bonding jumper.

3. Measure the electrical bonding between the P6-2 relay panel and P6 Load Control Center structure.

4. Group 5-7, 9, Configuration 2:

Remove and keep two GFI relays on the P6-2 relay panel, turn the relay sockets 180 degrees, then

install the kept relays in the new position.

5. Do a Ground Fault Interrupter (GFI) - Operational Test of the GFI relay installation for the fuel boost

pumps.

Group 1, 8:

PART 3 - THIS PART IS DELETED

1. Operators with Group 1 and Group 8 airplanes should contact The Boeing Company to get engineering

and accomplishment instructions for this change and do the instructions.

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BOEING SERVICE BULLETIN 737-28A1212

ALERT ALERT
Group 5-7, 9, Configuration 3:

PART 4 - MORE WORK - GFI RELAY POSITION CHANGE

1. Get access to the flight compartment.

2. Remove and keep two GFI relays on the P6-2 relay panel, turn the relay sockets 180 degrees, then

install the kept relays in the new position.

3. Measure the electrical bonding between each of the changed GFI relays and the P6-2 relay panel and

repair the bond if necessary.

4. Do a Ground Fault Interrupter (GFI) - Operational Test of the GFI relay installation for the related fuel

boost pumps.

EFFECTIVITY

737-100/-200/-200C/-300/-400/-500 Airplanes. Refer to Paragraph 1.A., Effectivity for the list of affected airplanes.

COMPLIANCE

Federal Aviation Administration (FAA) Airworthiness Directive AD 2011-12-09 is related to this service bulletin.

Group 1, 8:

Operators with Group 1 and Group 8 airplanes should contact The Boeing Company to get engineering and

accomplishment instructions for this change and do the instructions within 60 months after the effective date of

Revision 01 of this service bulletin.

Group 2-4, 10-13:

Boeing recommends that operators make the changes shown in this service bulletin within 60 months after the

effective date of Revision 01 of this service bulletin.

Group 5-7, 9:

Boeing recommends that operators make the changes shown in this service bulletin within 60 months after the

effective date of Revision 02 of this service bulletin.

INDUSTRY SUPPORT INFORMATION

Boeing warranty remedies are not available for the configuration changes given in this service bulletin.

MANPOWER

Refer to Paragraph 1.G., Manpower.

MATERIAL INFORMATION

Operator Supplied Parts/Materials.

Refer to Paragraph 2.A., Material - Price and Availability.

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ALERT ALERT
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ALERT ALERT
Commercial

Airplanes 737

Service Bulletin

ALERT

Number: 737-28A1212

Original Issue: July 23, 2009

Revision 2: October 18, 2012

ATA System: 2822

SUBJECT: FUEL - Engine Fuel Feed System - Fuel Pump Control Ground Fault Interrupter (GFI)

Relay Installation

THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH

1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO

THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO

THE NEW OWNER.

1. PLANNING INFORMATION

A. Effectivity

1. Airplanes

Refer to Service Bulletin Index D6-19567 Part 3 for Airplane Variable Number, Line Number, and

Serial Number data.

This service bulletin is for the airplanes shown below. Refer to PRR35440-10RS for data about

this change.

GROUP CONFIGURATION DESCRIPTION

737-100/200/200C Airplanes, line numbers 42 thru 291. Operators

should contact The Boeing Company to get engineering and

accomplishment instructions for this change and do the instructions.

1 -

737-100/200/200C/300/400 Airplanes, line numbers 292 thru 3132,

that require replacement of 6 Relays, without spacers, on the P6-2

panel, and changes to the W0044 Wire Bundle.

2 -

1 Airplanes that have not accomplished this service bulletin.

Airplanes that have accomplished the Original Issue, but not Revision

1 of this service bulletin.

2

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GROUP CONFIGURATION DESCRIPTION

737-200 Airplanes, line numbers 292 thru 985, delivered equipped

for Auxiliary Fuel Tanks, that require replacement of 8 Relays, without

spacers, on the P6-2 panel and changes to the W0044 Wire Bundle.

3 -

1 Airplanes that have not accomplished this service bulletin.

Airplanes that have accomplished the Original Issue, but not Revision

1 of this service bulletin.

2

737-200/300/400/500 Airplanes, line numbers 1494 thru 3132, that

require replacement of 6 Relays, with spacers, on the P6-2 panel.

4 -

1 Airplanes that have not accomplished this service bulletin.

Airplanes that have accomplished the Original Issue, but not Revision

1 of this service bulletin.

2

737-300/400/500 Airplanes, line numbers 1663 thru 3132, that require

replacement of 2 Relays without spacers and 4 Relays with spacers,

on the P6-2 panel.

5 -

1 Airplanes that have not accomplished this service bulletin.

Airplanes that have accomplished the Original Issue, but not Revision

1 of this service bulletin.

2

3 Airplanes that have accomplished Revision 1 of this service bulletin.

737-400 Airplanes, line numbers 1707 thru 3132, delivered equipped

for Auxiliary Fuel Tanks, that require replacement of 4 Relays without

spacers and 4 Relays with spacers, on the P6-2 panel, and changes

to the W0044 Wire Bundle.

6 -

1 Airplanes that have not accomplished this service bulletin.

Airplanes that have accomplished the Original Issue, but not Revision

1 of this service bulletin.

2

Airplanes, equipped with Auxiliary Fuel Tanks, that have accomplished

Revision 1 of this service bulletin.

3

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ALERT ALERT
GROUP CONFIGURATION DESCRIPTION

737-400 Airplanes, line numbers 1687, 1697 and 2043, delivered

equipped for Auxiliary Fuel Tanks, that require replacement of 2

Relays without spacers and 6 Relays with spacers, on the P6-2 panel,

and changes to the W0044 Wire Bundle.

7 -

1 Airplanes that have not accomplished this service bulletin.

Airplanes that have accomplished the Original Issue, but not Revision

1 of this service bulletin.

2

Airplanes, equipped with Auxiliary Fuel Tanks, that have accomplished

Revision 1 of this service bulletin.

3

737-100/200 Airplanes, line numbers 1 thru 41, that have different

service bulletin effectivities. Operators should contact The Boeing

Company to get engineering and accomplishment instructions for

this change and do the instructions.

8 -

737-400 Airplane, line number 2432, delivered equipped for Auxiliary

Fuel Tanks, that require replacement of 2 Relays without spacers

and 6 Relays with spacers, on the P6-2 panel, and changes to the

W0044 Wire Bundle.

9 -

1 Airplanes that have not accomplished this service bulletin.

Airplanes that have accomplished the Original Issue, but not Revision

1 of this service bulletin.

2

Airplanes, equipped with Auxiliary Fuel Tanks, that have accomplished

Revision 1 of this service bulletin.

3

737-200 Airplane, line number 1585, delivered equipped for Auxiliary

Fuel Tanks, that require replacement of 8 Relays, without spacers,

on the P6-2 panel and different changes to the W0044 Wire Bundle.

10 -

1 Airplanes that have not accomplished this service bulletin.

Airplanes that have accomplished the Original Issue, but not Revision

1 of this service bulletin.

2

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ALERT ALERT
GROUP CONFIGURATION DESCRIPTION

737-300 Airplanes, line numbers 1124 thru 1385, delivered equipped

for Auxiliary Fuel Tanks, that require replacement of 8 Relays, without

spacers, on the P6-2 panel and different changes to the W0044 Wire

Bundle.

11 -

1 Airplanes that have not accomplished this service bulletin.

Airplanes that have accomplished the Original Issue, but not Revision

1 of this service bulletin.

2

737-200 Airplanes, line numbers 458 thru 987, delivered with

provisional wires for Auxiliary Tanks, that require replacement of 8

Relays (or 6 without auxiliary tanks), without spacers, on the P6-2

panel and changes to the W0044 Wire Bundle.

12 -

1 Airplanes that have not accomplished this service bulletin.

Airplanes that have accomplished the Original Issue, but not Revision

1 of this service bulletin.

2

737-300 Airplanes, line numbers 1111 thru 3132, delivered with

provisional wires for Auxiliary Tanks, that require replacement of 8

Relays (or 6 without auxiliary tanks), without spacers, on the P6-2

panel and different changes to the W0044 Wire Bundle.

13 -

1 Airplanes that have not accomplished this service bulletin.

Airplanes that have accomplished the Original Issue, but not Revision

1 of this service bulletin.

2

Airplane Models:

737-100, 737-200, 737-200C, 737-300, 737-400, 737-500

Variable Number Group

PA001 - PA014 8

PA015 - PA022 1

PA099 8

PA231 - PA232 1

PC001 - PC005 1

PG001 - PG017 8

PG018 - PG075 1

PG199 8

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ALERT ALERT
Variable Number Group

PG201 - PG202 8

PG203 - PG230 1

PG251 - PG255 1

PG271 - PG273 8

PG274 - PG279 1

PG301 - PG302 8

PG303 - PG314 1

PG331 8

PG332 1

PG351 - PG356 1

PG375 1

PG401 - PG403 1

PG431 - PG442 1

PG471 - PG475 1

PG501 - PG505 1

PG571 - PG583 1

PG584 - PG586 2

PG621 - PG630 1

PG651 - PG652 1

PG704 - PG705 1

PH001 2

PH011 - PH013 2

PH021 - PH024 2

PH701 - PH715 1

PH731 - PH732 1

PH741 - PH742 1

PH743 2

PJ001 - PJ002 1

PJ003 - PJ006 2

PJ007 - PJ009 3

PJ031 - PJ032 1

PJ071 - PJ072 1

PJ101 - PJ104 1

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ALERT ALERT
Variable Number Group

PJ105 - PJ119 2

PJ201 - PJ219 3

PJ301 - PJ302 4

PJ551 - PJ561 4

PJ601 - PJ615 4

PJ811 6

PJ816 - PJ817 5

PK026 - PK029 2

PK041 - PK053 2

PK061 - PK067 2

PK068 - PK070 3

PK081 - PK082 2

PK091 - PK099 2

PK101 - PK103 2

PK111 - PK120 2

PK141 - PK146 2

PK201 - PK204 2

PK211 - PK223 2

PK231 - PK241 2

PK251 - PK256 2

PK257 12

PK258 2

PK271 - PK274 2

PK281 - PK289 2

PK291 2

PK301 - PK318 2

PK341 2

PK351 - PK355 2

PK356 - PK359 3

PK360 12

PK361 2

PK391 2

PK431 - PK433 2

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ALERT ALERT
Variable Number Group

PK451 - PK452 2

PK461 - PK469 2

PK495 2

PK501 2

PK502 - PK504 12

PK511 - PK515 2

PK519 2

PK521 - PK528 2

PK541 - PK565 2

PK581 2

PK591 - PK599 2

PK601 - PK606 2

PK607 - PK610 3

PK611 - PK617 2

PK621 - PK637 2

PK641 - PK642 2

PK661 3

PK662 - PK666 2

PK671 - PK681 2

PK691 - PK697 2

PK711 - PK716 2

PK731 - PK765 2

PK771 - PK779 2

PK801 - PK804 2

PK819 - PK827 2

PK830 2

PK861 - PK863 2

PK871 - PK872 12

PK873 3

PK874 12

PK881 - PK884 2

PK901 - PK938 2

PK971 - PK974 2

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ALERT ALERT
Variable Number Group

PL001 - PL028 2

PL061 2

PL081 2

PL101 - PL113 2

PL151 2

PL171 - PL172 2

PL201 - PL203 2

PL221 2

PL401 - PL408 2

PL409 - PL410 3

PL411 2

PL412 3

PL413 - PL417 2

PL421 12

PL441 2

PL451 - PL456 2

PL471 2

PL491 2

PL501 3

PL502 - PL503 12

PL504 - PL506 3

PL551 - PL562 2

PL581 2

PL601 - PL603 3

PL611 2

PL621 - PL626 2

PL631 - PL632 3

PL711 - PL712 1

PL716 1

PL717 - PL747 2

PL756 2

PL758 2

PL761 - PL770 2

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ALERT ALERT
Variable Number Group

PL781 - PL788 2

PL793 2

PL801 - PL803 1

PM001 - PM006 2

PM016 - PM017 2

PM021 - PM023 2

PM051 - PM066 2

PM101 - PM107 3

PM108 - PM119 12

PM141 - PM142 12

PM171 2

PM181 2

PM251 - PM255 2

PM281 - PM283 2

PM381 - PM399 2

PM401 - PM417 2

PM541 - PM550 2

PM551 - PM564 4

PN001 - PN002 3

PN021 - PN043 2

PN081 - PN086 2

PN101 - PN117 2

PN131 - PN163 2

PN401 - PN420 2

PN431 - PN433 2

PN451 - PN456 2

PN471 - PN474 2

PN481 2

PN491 - PN493 2

PN501 2

PN502 4

PN511 2

PN512 4

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ALERT ALERT
Variable Number Group

PN521 10

PP001 - PP054 2

PP101 - PP169 2

PP181 - PP187 2

PP188 - PP199 4

PP201 - PP205 2

PP221 2

PP231 - PP243 2

PP281 - PP286 2

PP301 - PP305 2

PP351 - PP353 2

PP376 - PP384 2

PP391 - PP393 2

PP401 - PP440 2

PP471 - PP475 11

PP501 - PP520 13

PP521 - PP522 2

PP631 - PP634 2

PP651 - PP652 2

PP671 - PP689 2

PP690 - PP694 11

PP695 - PP699 2

PP701 - PP706 2

PP707 - PP716 11

PP717 - PP733 2

PP771 - PP779 2

PP801 - PP808 2

PP821 - PP827 2

PP831 - PP848 2

PP851 - PP852 2

PP861 - PP877 2

PP891 - PP899 2

PP901 - PP936 2

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ALERT ALERT
Variable Number Group

PP946 - PP948 2

PP951 - PP952 2

PP961 - PP965 2

PP966 - PP967 4

PP981 - PP982 2

PP983 - PP990 4

PP991 2

PP993 4

PQ001 - PQ016 2

PQ026 - PQ041 2

PQ051 - PQ092 2

PQ101 - PQ199 2

PQ201 - PQ202 2

PQ221 - PQ230 4

PQ231 - PQ232 2

PQ233 - PQ237 4

PQ241 - PQ242 2

PQ243 4

PQ251 - PQ267 4

PQ281 - PQ299 4

PQ301 - PQ307 4

PQ331 - PQ332 4

PQ341 - PQ348 4

PQ361 - PQ373 4

PQ391 - PQ395 4

PQ401 - PQ418 4

PQ421 4

PQ431 - PQ438 4

PQ447 - PQ448 4

PQ451 4

PQ454 4

PQ471 - PQ475 4

PQ479 - PQ481 4

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ALERT ALERT
Variable Number Group

PQ486 - PQ487 4

PQ491 - PQ493 4

PQ771 - PQ772 4

PQ791 - PQ793 4

PQ801 - PQ805 4

PQ931 - PQ935 5

PQ951 5

PQ971 - PQ997 4

PR001 - PR017 4

PR021 - PR034 4

PR041 - PR045 5

PR061 - PR072 5

PR077 - PR082 5

PR091 - PR092 4

PR096 4

PR101 4

PR121 - PR122 4

PR131 - PR132 4

PR141 - PR143 4

PR161 - PR172 4

PR181 4

PS601 - PS631 2

PS636 - PS638 2

PS641 - PS644 2

PS651 - PS657 4

PS666 - PS669 4

PS691 - PS692 4

PS701 - PS706 2

PS751 - PS799 2

PS811 4

PS836 - PS837 4

PS841 - PS846 2

PS851 - PS852 2

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ALERT ALERT
Variable Number Group

PS856 2

PS861 - PS863 13

PS866 - PS868 13

PS871 - PS874 2

PS896 - PS897 2

PS901 - PS941 2

PS956 - PS957 13

PS961 - PS963 4

PS971 - PS978 4

PT001 - PT015 4

PT021 - PT031 4

PT041 - PT064 4

PT101 - PT105 4

PT121 - PT138 5

PT146 - PT148 4

PT161 - PT170 4

PT181 - PT188 5

PT211 - PT220 4

PT295 5

PT301 - PT309 4

PT331 - PT360 5

PT381 - PT399 4

PT401 - PT438 4

PT501 - PT517 4

PT561 - PT565 4

PT581 - PT586 4

PT611 - PT621 4

PT641 - PT644 4

PT651 - PT656 4

PT671 - PT672 4

PT681 - PT685 5

PT701 - PT703 4

PT716 - PT717 4

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ALERT ALERT
Variable Number Group

PT721 - PT725 4

PT801 - PT834 4

PT851 - PT854 4

PT871 - PT886 5

PT901 - PT930 4

PT971 - PT973 4

PT981 - PT985 4

PT996 4

PU001 - PU025 4

PU301 4

PU311 - PU313 4

PV001 2

PV002 - PV055 4

PV201 - PV209 4

PV226 - PV229 4

PV231 - PV237 5

PV271 - PV272 4

PV281 - PV287 5

PV296 4

PV301 - PV302 4

PV351 5

PV356 - PV357 4

PW001 - PW054 4

PW061 - PW068 4

PW072 4

PW086 - PW088 4

PW091 - PW094 4

PW101 - PW102 4

PW106 4

PW111 - PW120 4

PW156 - PW157 4

PW161 - PW171 4

PW201 - PW252 4

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ALERT ALERT
Variable Number Group

PW261 - PW268 4

PW271 - PW276 4

PW278 4

PW281 - PW293 4

PW296 4

PW301 - PW327 5

PW401 - PW408 4

PW411 - PW418 4

PW421 - PW424 4

PW431 - PW435 4

PW441 - PW450 5

PW461 - PW467 5

PW501 - PW504 5

PW511 - PW512 7

PW513 - PW522 6

PW524 6

PW525 - PW529 5

PW530 6

PW531 - PW550 4

PW556 - PW557 4

PW561 - PW564 5

PW571 - PW576 5

PW591 - PW596 4

PW611 - PW622 4

PW631 - PW637 4

PW661 - PW662 4

PW681 - PW683 4

PW701 7

PW702 9

PW711 - PW717 5

PW741 - PW742 4

PW761 4

PW771 4

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ALERT ALERT
Variable Number Group

PW831 4

PW851 - PW856 4

PX071 1

PX701 1

PY001 - PY008 1

PY021 1

PY022 2

PY031 1

PY036 - PY037 2

PY046 - PY048 2

PY051 - PY053 2

PY056 - PY057 2

PY101 - PY103 2

PY111 - PY113 2

PY131 - PY135 2

PY141 - PY143 2

PY151 - PY154 2

PY156 - PY157 2

PY161 - PY162 2

PY166 2

PY191 2

PY201 2

PY221 - PY222 2

PY231 2

PY241 - PY244 2

PY270 - PY275 2

PY281 2

PY286 2

PY301 - PY304 1

PY321 - PY323 1

PY341 - PY346 1

PY361 - PY362 1

PY381 1

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ALERT ALERT
Variable Number Group

PY401 2

PY409 - PY411 2

PY421 - PY422 2

PY441 2

PY451 2

PY461 - PY463 2

PY591 - PY595 2

PY611 - PY612 2

PY621 2

PY631 2

PY651 2

PY671 - PY672 2

PY721 2

PY741 2

2. Spares Affected

None.

B. Concurrent Requirements

None.

C. Reason

This service bulletin gives the instructions to replace the power control relays for the fuel boost pumps.

The relays are located in the P6 circuit breaker panel in the flight compartment. The new relays include

a ground fault interrupt (GFI) feature. The GFI relay feature will protect the fuel pumps from damage

caused by electrical arcing because the electrical power will be removed from the pump if a ground

fault is detected. Electrical arcing could create a possible source of ignition of flammable fuel vapors

in the fuel tanks. Ignition of flammable fuel vapors could cause a fire or explosion which could put the

airplane in an unsafe condition.

This service bulletin is the result of the safety assessments conducted by Boeing under SFAR 88, "Fuel

Tank System Fault Tolerance Evaluation Requirements".

This change affects section 9 of the Maintenance Planning Data (MPD) Document. The Airworthiness

Limitations (AWL) "28-AWL-23" (737-100/200/200C airplanes) and "28-AWL-22" (737-300/400/500

airplanes) are related to this service bulletin.

Boeing Fleet Team Digest 737 FTD 28-04005 is related to this service bulletin.

Boeing Service Letter 737-SL-28-070 is related to this service bulletin.

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ALERT ALERT
Revision 1 was sent to change the sections that follow:

1. Airplanes PM541-PM548 are added to the service bulletin effectivity. Added new airplane

configurations to the group configuration table.

2. Group 12 and Group 13 had been added to the configuration table. Airplanes delivered with Auxiliary

Tank wire provisions have been moved to Group 12 and Group 13. Group/Configuration information

has been added to define those airplanes that have already accomplished initial release of the

service bulletin.

3. Changed the concurrent requirements reference from original issue of BAE Component Service

Bulletin 65-49808-24-01 to Revision 1 of the BAE Component Service Bulletin 65-49808-24-01.

4. Removed the reference to the Fault Isolation Manual and changed the IPC reference in Paragraph

1.K., Publications affected. The 737-100/-200/-300/-400/-500 airplane models do not have a Fault

Isolation Manual.

5. Task hour tables had been added for each airplane group configuration. The task hour estimates

were changed to include the removal and installation of the galley number one.

6. Three kits, availability, and price information was added to paragraph 2.A. Material Information.

7. The work instructions were changed to include:

a. The removal and installation of the galley number one to get access to the work location.

b. The installation of a bonding jumper.

c. To prepare/clean the contact surfaces of the relays and mounting panel to obtain the required

electrical bonding.

d. To measure the bonding resistance between the GFI relays and mounting panel.

e. To measure the bonding resistance between the mounting panel and P6 Load Control Center

structure.

f. Added Part 2 and Part 3 for airplanes that incorporated original issue of the service bulletin.

8. Terminology has been changed in the Work Instructions to agree with the terminology defined in

Paragraph 3.A. General Information - Notes.

9. Figure 1 was changed to change the reference to Revision 1 of the BAE Component Service

Bulletin 65-49808-24-01. Step was added to measure the electrical bonding resistance between

Relay Module Assemblies M181, M182, and M183 and the P6 Load Control Center structure.

10. Figure 2, 3, 4, 5, 6, 7 have been changed to prepare/clean the contact surfaces of the relays and

mounting panel in order to obtain the required electrical bonding.

11. Figure 22 has been added. this figure provides instructions to add a bonding jumper between relay

mounting panel and P6 Load Control Center structure and measure the bonding resistance between

the relay mounting panel and P6 Load Control Center structure.

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ALERT ALERT
12. Appendix A that provides information for electrical bonding was added to Paragraph 3.A., Work

Instructions.

Revision 2 is sent to update the installation of new GFI relays because the GFI system might not

function correctly after their installation on Groups 5, 6, 7 and 9 airplanes. Boeing received a report

from one operator that told of incorrect operation of new 9524G-10674 GFI relays. A subsequent

investigation and test found that Electromagnetic Interference (EMI), between the new 9524G-10674

relays and adjacent KCG-X4L-001 relays could cause problems with the function of new relays and

thus the operation of GFI system. The instructions have therefore been updated to change the position

of the GFI relays. Other groups are not affected by this problem because of differences in the P6-2

relay panel layout. This revision is a final solution to the problem described in 737-28A1212 IN 02 and

requires no new parts to be supplied or kit changes. Operators of airplanes in Groups 5, 6 and 7 can

now continue to incorporate this service bulletin at this revision.

In addition, at revision 2, instructions to change airplane line numbers 1-291, in Groups 1 and 8, are

removed. Operators with these airplanes should contact The Boeing Company to get engineering and

accomplishment instructions for this change.

D. Description

Group 2-7, 9-13, Configuration 1:

PART 1 - GROUND STUDS AND BONDING JUMPER INSTALLATION AND FUEL BOOST PUMP

RELAYS REPLACEMENT

1. Get access to the flight compartment.

2. At the P6 Load Control Center install two ground studs and a ground bonding jumper.

3. Measure the electrical bonding between the P6-2 relay panel and P6 Load Control Center structure.

4. Replace relays on the P6-2 relay panel with new Ground Fault Interrupt (GFI) relays as follows:

a. Group 2, 4, Configuration 1:

Replace six relays.

b. Group 3, 10-13, Configuration 1:

Replace eight relays.

c. Group 5, Configuration 1:

Replace six relays, with R18 and R19 turned 180 degrees.

d. Group 6-7, 9, Configuration 1:

Replace eight relays, with R146 and R147 turned 180 degrees.

5. Measure the electrical bonding between each of the new GFI relays and the P6-2 relay panel and

repair the bond if necessary.

6. Group 2-3, 6-7, 9-13, Configuration 1:

Change the W0044 wire bundle.

7. Do a Ground Fault Interrupter (GFI) - Operational Test of the GFI relay installation for the fuel

boost pumps.

Export Controlled ECCN: 9E991 - BOEING

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BOEING SERVICE BULLETIN 737-28A1212

ALERT ALERT
Group 2-7, 9-13, Configuration 2:

PART 2 - MORE WORK - GROUND STUDS AND BONDING JUMPER INSTALLATION AND GFI

RELAY POSITION CHANGE

1. Get access to the flight compartment.

2. At the P6 Load Control Center install two ground studs and a ground bonding jumper.

3. Measure the electrical bonding between the P6-2 relay panel and P6 Load Control Center structure.

4. Group 5-7, 9, Configuration 2:

Remove and keep two GFI relays on the P6-2 relay panel, turn the relay sockets 180 degrees,

then install the kept relays in the new position.

5. Do a Ground Fault Interrupter (GFI) - Operational Test of the GFI relay installation for the fuel

boost pumps.

Group 1, 8:

PART 3 - THIS PART IS DELETED

1. Operators with Group 1 and Group 8 airplanes should contact The Boeing Company to get

engineering and accomplishment instructions for this change and do the instructions.

Group 5-7, 9, Configuration 3:

PART 4 - MORE WORK - GFI RELAY POSITION CHANGE

1. Get access to the flight compartment.

2. Remove and keep two GFI relays on the P6-2 relay panel, turn the relay sockets 180 degrees,

then install the kept relays in the new position.

3. Measure the electrical bonding between each of the changed GFI relays and the P6-2 relay panel

and repair the bond if necessary.

4. Do a Ground Fault Interrupter (GFI) - Operational Test of the GFI relay installation for the related

fuel boost pumps.

Revision 1 - More work is necessary on airplanes changed in accordance with the original issue of this

service bulletin. Group 2 through 7 Airplanes and Group 9 through 11 airplanes that incorporated

original issue of this service bulletin have to incorporate Accomplishment Instructions, Work instructions,

Part 2 that provides work instructions to install a Bonding Jumper between the relay mounting panel

and P6 Load Control Center structure, and measure the electrical bonding resistance between the GFI

relays and the relay mounting panel. Group 1 and Group 8 airplanes that incorporated original issue

of this service bulletin have to incorporate Accomplishment Instructions, Work instructions, Part 3 that

provides work instructions to measure the electrical bonding resistance between the GFI relays and

the Relay Module Assemblies M181, M182, and M183 in accordance with Revision 1 of BAE Service

Bulletin 65-49808-24-01, and to measure the electrical bonding resistance between the Relay Module

Assemblies M181, M182, and M183 and the P6 Load Control Center structure.

Revision 2 - More work is necessary for Group 5, 6, 7 and 9 airplanes that have been changed in

accordance with the Original Issue or Revision 1 of this service bulletin:-

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BOEING SERVICE BULLETIN 737-28A1212

ALERT ALERT
– For airplanes that have incorporated the Original Issue of this service bulletin, but not Revision 1,

it is necessary to change the position of two Ground Fault Interrupt (GFI) relays, on the P6-2 relay

panel, install a bonding jumper between the P6-2 relay panel and P6 Load Control Center structure,

do a bonding check of the GFI relays and do a GFI operational test. This work is identified as

Configuration 2 for these groups.

– For airplanes that have incorporated Revision 1 of this service bulletin, it is necessary to change

the position of two GFI relays on the P6-2 relay panel, do a bonding check and a GFI operational

test, for related fuel boost pumps. This work is identified as Configuration 3 for these groups.

Revision 2 - More work is necessary for Group 2-4 and Group 10-13 airplanes that have been changed

in accordance with the Original Issue of this service bulletin. It is necessary to install a bonding jumper

between the P6-2 relay panel and P6 Load Control Center structure, then do a GFI operational test of

the fuel boost pumps. This work is identified as Configuration 2 for these groups.

Revision 2 - No more work is necessary for Group 2-4 and Group 10-13 airplanes that have been

changed in accordance with Revision 1 of this service bulletin.

The work in this service bulletin is done in the maintenance zone(s) given below.

Group 1:

Affected Maintenance Zones

Model Zone

737-100, 737-200, 737-200C 1-2

Group 2:

Affected Maintenance Zones

Model Zone

737-200, 737-200C 1-2

Group 2:

Affected Maintenance Zones

Model Zone

737-300, 737-400 102

Group 3-4, 10, 12:

Affected Maintenance Zones

Model Zone

737-200 1-2

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BOEING SERVICE BULLETIN 737-28A1212

ALERT ALERT
Group 4-5:

Affected Maintenance Zones

Model Zone

737-300, 737-400, 737-500 102

Group 6-7, 9:

Affected Maintenance Zones

Model Zone

737-400 102

Group 8:

Affected Maintenance Zones

Model Zone

737-100, 737-200 1-2, 3-5, 4-5

Group 11, 13:

Affected Maintenance Zones

Model Zone

737-300 102

E. Compliance

Federal Aviation Administration (FAA) Airworthiness Directive AD 2011-12-09 is related to this service

bulletin.

Group 1, 8:

Operators with Group 1 and Group 8 airplanes should contact The Boeing Company to get engineering

and accomplishment instructions for this change and do the instructions within 60 months after the

effective date of Revision 01 of this service bulletin. .

Group 2-7, 9-13:

Boeing recommends that operators make the changes shown in this service bulletin within 60 months

after the effective date of Revision 02 of this service bulletin.

F. Approval

This service bulletin was examined by the Federal Aviation Administration (FAA). The changes specified

in this service bulletin comply with the applicable regulations and are FAA approved, as well as European

Aviation Safety Agency (EASA)/Joint Aviation Authorities (JAA) approved for all EASA/JAA approved

airplanes listed in the service bulletin effectivity. This service bulletin and its approval were based on

the airplane in its original Boeing delivery configuration or as modified by other approved Boeing

changes.

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BOEING SERVICE BULLETIN 737-28A1212

ALERT ALERT
If an airplane has a non-Boeing modification or repair that affects a component or system also affected

by this service bulletin, the operator is responsible for obtaining appropriate regulatory agency approval

before incorporating this service bulletin.

In addition, the Manager of the FAA Seattle Aircraft Certification Office approves the action (i.e. inspection

or modification) defined in this service bulletin as an alternative method of compliance to the requirements

of paragraph (g), (h), (i), (j) and (k) of AD 2011-12-09 for airplanes line numbers 292 through 3132. All

provisions of AD 2011-12-09 that are not specifically referenced in the above statement remain fully

applicable and must be complied with.

The AMOC for Revision 2 of this bulletin does not apply to Group 1 and 8 airplanes (line numbers 1

thru 291), operators should contact the Boeing company for more instructions to do this change.

G. Manpower

The table below shows an estimate of the task-hours necessary to do this change for each airplane.

This estimate is for direct labor only, done by an experienced crew. Adjust the estimate with operator

task-hour data if necessary. The estimate does not include lost time. These are some examples of lost

time:

— Time to adjust to the workplace

— Time to schedule the work

— Time to examine the work

— Time to cure the materials

— Time to make the parts

— Time to find the tools.

Group 2, Configuration 1:

PART 1 - GROUND STUDS AND BONDING JUMPER INSTALLATION AND FUEL BOOST PUMP

RELAYS REPLACEMENT

Task Number of Persons Task-Hours Elapsed Hours

Open Access 1 0.50 0.50

Removal of the Galley number one 2 8.00 4.00

FIGURE 2 1 3.50 3.50

FIGURE 9 1 0.40 0.40

FIGURE 22 1 1.00 1.00

Close Access 1 0.50 0.50

Installation of the Galley number 3 12.00 4.00

one

Test 2 2.50 1.25

TOTAL FOR EACH AIRPLANE - PART 1 28.40 15.15

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BOEING SERVICE BULLETIN 737-28A1212

ALERT ALERT
Group 3, 12, Configuration 1:

PART 1 - GROUND STUDS AND BONDING JUMPER INSTALLATION AND FUEL BOOST PUMP

RELAYS REPLACEMENT

Task Number of Persons Task-Hours Elapsed Hours

Open Access 1 0.50 0.50

Removal of the Galley number one 2 8.00 4.00

FIGURE 3 1 4.50 4.50

FIGURE 10 1 1.60 1.60

FIGURE 22 1 1.00 1.00

Close Access 1 0.50 0.50

Installation of the Galley number 3 12.00 4.00

one

Test 2 2.50 1.25

TOTAL FOR EACH AIRPLANE - PART 1 30.60 17.35

Group 4, Configuration 1:

PART 1 - GROUND STUDS AND BONDING JUMPER INSTALLATION AND FUEL BOOST PUMP

RELAYS REPLACEMENT

Task Number of Persons Task-Hours Elapsed Hours

Open Access 1 0.50 0.50

FIGURE 4 1 3.50 3.50

FIGURE 22 1 1.00 1.00

Close Access 1 0.50 0.50

Test 2 2.50 1.25

TOTAL FOR EACH AIRPLANE - PART 1 8.00 6.75

Group 5, Configuration 1:

PART 1 - GROUND STUDS AND BONDING JUMPER INSTALLATION AND FUEL BOOST PUMP

RELAYS REPLACEMENT

Task Number of Persons Task-Hours Elapsed Hours

Open Access 1 0.50 0.50

FIGURE 5 1 5.00 5.00

FIGURE 22 1 1.00 1.00

Close Access 1 0.50 0.50

Test 2 2.50 1.25

TOTAL FOR EACH AIRPLANE - PART 1 9.50 8.25

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BOEING SERVICE BULLETIN 737-28A1212

ALERT ALERT
Group 6, Configuration 1:

PART 1 - GROUND STUDS AND BONDING JUMPER INSTALLATION AND FUEL BOOST PUMP

RELAYS REPLACEMENT

Task Number of Persons Task-Hours Elapsed Hours

Open Access 1 0.50 0.50

Removal of the Galley number one 2 8.00 4.00

FIGURE 6 1 5.50 5.50

FIGURE 11 1 0.40 0.40

FIGURE 22 1 1.00 1.00

Close Access 1 0.50 0.50

Installation of the Galley number 3 12.00 4.00

one

Test 2 2.50 1.25

TOTAL FOR EACH AIRPLANE - PART 1 30.40 17.15

Group 7, 9, Configuration 1:

PART 1 - GROUND STUDS AND BONDING JUMPER INSTALLATION AND FUEL BOOST PUMP

RELAYS REPLACEMENT

Task Number of Persons Task-Hours Elapsed Hours

Open Access 1 0.50 0.50

Removal of the Galley number one 2 8.00 4.00

FIGURE 7 1 6.00 6.00

FIGURE 11 1 0.40 0.40

FIGURE 22 1 1.00 1.00

Close Access 1 0.50 0.50

Installation of the Galley number 3 12.00 4.00

one

Test 2 2.50 1.25

TOTAL FOR EACH AIRPLANE - PART 1 30.90 17.65

Group 10, Configuration 1:

PART 1 - GROUND STUDS AND BONDING JUMPER INSTALLATION AND FUEL BOOST PUMP

RELAYS REPLACEMENT

Task Number of Persons Task-Hours Elapsed Hours

Open Access 1 0.50 0.50

Removal of the Galley number one 2 8.00 4.00

FIGURE 3 1 4.50 4.50

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BOEING SERVICE BULLETIN 737-28A1212

ALERT ALERT
Group 10, Configuration 1:

PART 1 - GROUND STUDS AND BONDING JUMPER INSTALLATION AND FUEL BOOST PUMP

RELAYS REPLACEMENT

Task Number of Persons Task-Hours Elapsed Hours

FIGURE 12 1 0.40 0.40

FIGURE 22 1 1.00 1.00

Close Access 1 0.50 0.50

Installation of the Galley number 3 12.00 4.00

one

Test 2 2.50 1.25

TOTAL FOR EACH AIRPLANE - PART 1 29.40 16.15

Group 11, 13, Configuration 1:

PART 1 - GROUND STUDS AND BONDING JUMPER INSTALLATION AND FUEL BOOST PUMP

RELAYS REPLACEMENT

Task Number of Persons Task-Hours Elapsed Hours

Open Access 1 0.50 0.50

Removal of the Galley number one 2 8.00 4.00

FIGURE 3 1 4.50 4.50

FIGURE 13 1 1.60 1.60

FIGURE 22 1 1.00 1.00

Close Access 1 0.50 0.50

Installation of the Galley number 3 12.00 4.00

one

Test 2 2.50 1.25

TOTAL FOR EACH AIRPLANE - PART 1 30.60 17.35

Group 2-4, 10-13, Configuration 2:

PART 2 - MORE WORK - GROUND STUDS AND BONDING JUMPER INSTALLATION

Task Number of Persons Task-Hours Elapsed Hours

Open Access 1 0.50 0.50

FIGURE 22 1 1.00 1.00

Close Access 1 0.50 0.50

Test 2 2.50 1.25

TOTAL FOR EACH AIRPLANE - PART 2 4.50 3.25

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BOEING SERVICE BULLETIN 737-28A1212

ALERT ALERT
Group 5, Configuration 2:

PART 2 - MORE WORK - GROUND STUDS AND BONDING JUMPER INSTALLATION AND GFI

RELAY POSITION CHANGE

Task Number of Persons Task-Hours Elapsed Hours

Open Access 1 0.50 0.50

FIGURE 22 1 1.00 1.00

FIGURE 23 1 1.50 1.50

Close Access 1 0.50 0.50

Test 2 2.50 1.25

TOTAL FOR EACH AIRPLANE - PART 2 6.00 4.75

Group 6, Configuration 2:

PART 2 - MORE WORK - GROUND STUDS AND BONDING JUMPER INSTALLATION AND GFI

RELAY POSITION CHANGE

Task Number of Persons Task-Hours Elapsed Hours

Open Access 1 0.50 0.50

FIGURE 22 1 1.00 1.00

FIGURE 24 1 1.50 1.50

Close Access 1 0.50 0.50

Test 2 2.50 1.25

TOTAL FOR EACH AIRPLANE - PART 2 6.00 4.75

Group 7, 9, Configuration 2:

PART 2 - MORE WORK - GROUND STUDS AND BONDING JUMPER INSTALLATION AND GFI

RELAY POSITION CHANGE

Task Number of Persons Task-Hours Elapsed Hours

Open Access 1 0.50 0.50

FIGURE 22 1 1.00 1.00

FIGURE 25 1 1.50 1.50

Close Access 1 0.50 0.50

Test 2 2.50 1.25

TOTAL FOR EACH AIRPLANE - PART 2 6.00 4.75

Group 1, 8:

PART 3 - THIS PART IS DELETED

1. Operators with Group 1 and Group 8 airplanes should contact The Boeing Company to get

engineering and accomplishment instructions for this change and do the instructions.

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BOEING SERVICE BULLETIN 737-28A1212

ALERT ALERT
Group 5, Configuration 3:

PART 4 - MORE WORK - GFI RELAY POSITION CHANGE

Task Number of Persons Task-Hours Elapsed Hours

Open Access 1 0.50 0.50

FIGURE 23 1 1.50 1.50

Close Access 1 0.50 0.50

Test 2 1.50 0.75

TOTAL FOR EACH AIRPLANE - PART 4 4.00 3.25

Group 6, Configuration 3:

PART 4 - MORE WORK - GFI RELAY POSITION CHANGE

Task Number of Persons Task-Hours Elapsed Hours

Open Access 1 0.50 0.50

FIGURE 24 1.50 1.50

Close Access 1 0.50 0.50

Test 2 1.50 0.75

TOTAL FOR EACH AIRPLANE - PART 4 4.00 3.25

Group 7, 9, Configuration 3:

PART 4 - MORE WORK - GFI RELAY POSITION CHANGE

Task Number of Persons Task-Hours Elapsed Hours

Open Access 1 0.50 0.50

FIGURE 25 1 1.50 1.50

Close Access 1 0.50 0.50

Test 2 1.50 0.75

TOTAL FOR EACH AIRPLANE - PART 4 4.00 3.25

H. Weight and Balance Changes

None.

I. Electrical Load Data

Group 1, 8:

Operators with Group 1 and Group 8 airplanes should contact The Boeing Company to get engineering

and accomplishment instructions for this change and do the instructions.

1. Direct Current (DC) Loads

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BOEING SERVICE BULLETIN 737-28A1212

ALERT ALERT
Airplanes Amperes Bus

Group 2 - 0.71 DC Bus 1

- 0.71 DC Bus 2

Groups 3, 10, 11, 12 and 13 - 0.95 DC Bus 1

- 0.95 DC Bus 2

Group 4 + 0.03 DC Bus 1

+ 0.03 DC Bus 2

Group 5 - 0.22 DC Bus 1

- 0.22 DC Bus 2

Group 6 - 0.46 DC Bus 1

- 0.46 DC Bus 2

Group 7, 9 - 0.21 DC Bus 1

- 0.21 DC Bus 2

2. Type

Continuous.

J. References

1. Existing Data:

a. Engineering Change Memo PRR 35440-10RS.

b. Boeing Service Bulletin 737-24-1145.

c. Boeing Service Letter 737-SL-28-070.

d. Federal Aviation Administration (FAA) Airworthiness Directive (AD) 2011-12-09.

e. Service Bulletin Index D6-19567.

f. Standard Overhaul Practices Manual (SOPM) 20-11-03, 20-41-02, 20-43-03, 20-60-02.

g. Standard Wiring Practices Manual (SWPM) 20-00-11, 20-10-11, 20-10-12, 20-10-19, 20-20-00,

20-30-12, 20-60-00, 20-81-11, 20-81-22.

h. 737 Fleet Team Digest (FTD) 28-04005.

i. 737-100/200 Aircraft Maintenance Manual (AMM) 24-22-00, 25-11-0, 25-11-11, 25-16-11,

25-31-11, 28-22-18, 28-22-41.

j. 737-100/200 Structural Repair Manual (SRM) 51-30-02, 51-30-05.

k. 737-100/200 Wiring Diagram Manual (WDM) 28-23-01, 28-23-02.

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BOEING SERVICE BULLETIN 737-28A1212

ALERT ALERT
l. 737-300/400/500 Aircraft Maintenance Manual (AMM) 24-22-00, 25-11-11, 25-11-21, 25-31-11,

28-22-18, 28-22-41.

m. 737-300/400/500 Wiring Diagram Manual (WDM) 28-23-01, 28-23-02.

n. 737-300 Structural Repair Manual (SRM) 51-40-05.

o. 737-400 Structural Repair Manual (SRM) 51-40-05.

p. 737-500 Structural Repair Manual (SRM) 51-40-05.

2. Data Supplied with this Service Bulletin:

None.

3. Installation Drawings Used in the Preparation of this Service Bulletin:

Drawing Number Title

69-73627-( ) RELAY ASSY - LOAD CONTROL CENTER

65-49815 LOAD CONTROL CENTER (STRUCTURE) P-6 PANEL

65C25703 LOAD CONTROL CENTER INSTL - P6 PANEL

These drawings were used to prepare this service bulletin. These drawings are not necessary to

make the specified changes, and are not supplied with this service bulletin. These drawings may

not be applicable to all airplane configurations or operators.

K. Publications Affected

1. Publications:

Publication Chapter-Section

737 Maintenance Manual 28-22

737 Wiring Diagram Manual 28-23, Equipment List

737-100/200 Illustrated Parts Catalog 24-50, 28-20

737-300/400/500 Illustrated Parts Catalog 28-22, 28-23

737 Schematic Diagram 28-20

737 Maintenance Planning Document Section 9

2. Damage Tolerance Based Structural Inspections:

Boeing has evaluated the repairs and/or changes in this service bulletin for effects on Fatigue

Critical Structure (FCS) and for changes to Damage Tolerance Inspections (DTI) required in the

Maintenance Program. This service bulletin does not affect FCS, therefore DTIs are not necessary.

L. Interchangeability and Intermixability of Parts

Accomplishment of this service bulletin does not affect interchangeability or intermixability of parts.

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BOEING SERVICE BULLETIN 737-28A1212

ALERT ALERT
M. Software Accomplishment Summary

Not affected.

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ALERT ALERT
Export Controlled ECCN: 9E991 - BOEING

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BOEING SERVICE BULLETIN 737-28A1212

ALERT ALERT

BLANK PAGE
2. MATERIAL INFORMATION

A. Material - Price and Availability

Boeing can supply the kits shown in Paragraph 2.C., Parts Necessary for Each Airplane. Operators

are encouraged to share schedule requirements with Boeing for incorporation of the service bulletin.

The kits are subject to the terms and conditions of the Boeing standard purchase order acknowledgment.

Prices are in United States Dollars. Terms: Net 30 days.

Reference this service bulletin and submit your purchase order by one of these methods:

1. Order on-line via ATA Spec 2000 or The Boeing PART Page

2. Fax to (206) 662-7145

Group 1, 8:

Operators with Group 1 and Group 8 airplanes should contact The Boeing Company to get engineering

and accomplishment instructions for this change and do the instructions.

Group 2, Configuration 1:

REFER TO THE BOEING PART PAGE ON MYBOEINGFLEET.COM OR CONTACT FIRST RESPONDER

AT FR@BOEING.COM FOR THE LATEST REORDER LEAD TIME (ROLT) AND PRICE INFORMATION

Unit Price as of

the Revision 02

date of this Service Bulletin (US

Dollars)

ROLT as of the

Revision 02 date

of this Service

Bulletin (Calendar

Days)

Kit Number Name Date QTY

KIT - RETROFIT GFI 09/07/10 262 189 $326.00

RELAYS IN P6 - NONAUX CONFIGURATION

65C37854-12

Group 3, 6-7, 9-13, Configuration 1:

REFER TO THE BOEING PART PAGE ON MYBOEINGFLEET.COM OR CONTACT FIRST RESPONDER

AT FR@BOEING.COM FOR THE LATEST REORDER LEAD TIME (ROLT) AND PRICE INFORMATION

Unit Price as of

the Revision 02

date of this Service Bulletin (US

Dollars)

ROLT as of the

Revision 02 date

of this Service

Bulletin (Calendar

Days)

Kit Number Name Date QTY

KIT - RETROFIT GFI 09/07/10 24 189 $354.00

RELAYS IN P6 - AUX

OR AUX PROVISIONS

CONFIGURATION

65C37854-13 (a)

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BOEING SERVICE BULLETIN 737-28A1212

ALERT ALERT
Group 3, 6-7, 9-13, Configuration 1:

REFER TO THE BOEING PART PAGE ON MYBOEINGFLEET.COM OR CONTACT FIRST RESPONDER

AT FR@BOEING.COM FOR THE LATEST REORDER LEAD TIME (ROLT) AND PRICE INFORMATION

Unit Price as of

the Revision 02

date of this Service Bulletin (US

Dollars)

ROLT as of the

Revision 02 date

of this Service

Bulletin (Calendar

Days)

Kit Number Name Date QTY

(a) Airplanes in Group 12 and 13 have been delivered with wire provisions for Auxiliary Tank installation. If

Auxiliary Tanks have been installed on these airplanes operators need to order this kit. If Auxiliary Tanks

have not been installed on these airplanes there are more parts than necessary in this kit. Operators need

to order only the necessary parts to incorporate this service bulletin. The necessary parts can be ordered

as end item parts. Contact Boeing Spares for ordering the necessary end item parts from kit 65C37854-

13.

Group 2-3, Configuration 2; Group 4; Group 5, Configuration 1-2; Group 6-7, 9-13, Configuration 2:

REFER TO THE BOEING PART PAGE ON MYBOEINGFLEET.COM OR CONTACT FIRST RESPONDER

AT FR@BOEING.COM FOR THE LATEST REORDER LEAD TIME (ROLT) AND PRICE INFORMATION

Unit Price as of

the Revision 02

date of this Service Bulletin (US

Dollars)

ROLT as of the

Revision 02 date

of this Service

Bulletin (Calendar

Days)

Kit Number Name Date QTY

KIT - RETROFIT 09/07/10 33 189 $4.50

BONDING JUMPER

65C37854-14

Group 5-7, 9, Configuration 3:

None.

B. Industry Support Information

Boeing warranty remedies are not available for the configuration changes given in this service bulletin.

C. Parts Necessary for Each Airplane

1. Kits/Parts:

To get the kits/parts shown below, refer to Paragraph 2.A., Material - Price and Availability.

NOTE: One top kit and the items shown in Paragraph 2.C.2., Parts and Materials Supplied by

the Operator, are necessary for each airplane.

Group 1, 8:

Operators with Group 1 and Group 8 airplanes should contact The Boeing Company to get

engineering and accomplishment instructions for this change and do the instructions.

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BOEING SERVICE BULLETIN 737-28A1212

ALERT ALERT
Group 2-3, 6-7, 9-13, Configuration 1:

Kit 65C37854

Existing Part Notes

Number

New Part Number QTY Name

-12 -13

KIT - RETROFIT,

GFI RELAYS IN P6

- NON-AUX CONFIGURATION

65C37854-12 - .

KIT - RETROFIT,

GFI RELAYS IN P6

- AUX OR AUX

PROVISIONS

CONFIGURATION

65C37854-13 . -

KIT - RETROFIT

BONDING

JUMPER

65C37854-14 1 1

TOP KIT - GFI RELAYS IN P6 -

NON-AUX CONFIGURATION

61-74479-1 1 .

TOP KIT - GFI RELAYS IN P6 - AUX

OR AUX PROVISIONS CONFIGURATION

61-74479-2 . 1

Group 2-4; Group 5, Configuration 1-2; Group 6, Configuration 1-2; Group 7, Configuration

1-2; Group 9, Configuration 1-2; Group 10-13:

Kit 65C37854

Existing Part Notes

Number

New Part Number QTY Name

-14

KIT - RETROFIT

BONDING

JUMPER

65C37854-14 -

BONDING

JUMPER

BACJ40K5A5A6 1

BACN10YR3CD 2 NUT

BACS12GU3K10 2 SCREW (a)

NAS1149D0316H 6 WASHER

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BOEING SERVICE BULLETIN 737-28A1212

ALERT ALERT
Group 2-4; Group 5, Configuration 1-2; Group 6, Configuration 1-2; Group 7, Configuration

1-2; Group 9, Configuration 1-2; Group 10-13:

Kit 65C37854

Existing Part Notes

Number

New Part Number QTY Name

-14

(a) If grip length shown is not available at Boeing, fasteners supplied in kits

may be one grip length longer than indicated. Also, if any fasteners part

numbers listed are not available or have been superseded, substitute

fasteners may be supplied in kits.

Group 2-3, 6-7, 9-13, Configuration 1:

Kit 61-74479

New Part Number Name Notes -102 -101 -2 -1

61-74479-1 . . . - Top Kit, GFI Relays in P6 - Non- Aux Configuration (a)

Top Kit, GFI Relays in P6 - Aux or Aux Provisions (b)

Configuration

61-74479-2 . . - .

61-74479-101 . . . 1 Wire Kit, W0044 Wire Bundle

61-74479-102 . . 1 . Wire Kit, W0044 Wire Bundle

61-74479-2001 . . 1 1 Lacing Tape, White (a)

61-74479-2002 . . 1 1 Filler Wire (b)

Connector Identification Tape, Imprinted "D01606

M/W R00055 CTR R B/P"

61-74478-10301 1 1 . .

Connector Identification Tape, Imprinted "D01608

M/W R00054 CTR L B/P"

61-74478-10302 1 1 . .

Connector Identification Tape, Imprinted "D01818

M/W R00146 AFT AUX FWD BOOST PUMP"

61-74478-10401 1 . . .

Connector Identification Tape, Imprinted "D01820

M/W R00147 AFT AUX AFT BOOST PUMP"

61-74478-10402 1 . . .

Connector Identification Tape, Imprinted "D01602

M/W R00020 AFT B/P 2"

61-74479-10101 1 1 . .

Connector Identification Tape, Imprinted "D01604

M/W R00021 FWD B/P 2"

61-74479-10102 1 1 . .

Connector Identification Tape, Imprinted "D01610

M/W R00019 FWD B/P 1"

61-74479-10103 1 1 . .

Connector Identification Tape, Imprinted "D01612

M/W R00018 AFT B/P 1"

61-74479-10104 1 1 . .

BACC47CP2T 18 14 . . Contact

(a) Make from BMS 13-54, Type 3, Class 1, length as required.

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ALERT ALERT
Group 2-3, 6-7, 9-13, Configuration 1:

Kit 61-74479

New Part Number Name Notes -102 -101 -2 -1

(b) Make from BMS 13-48 Type 10, Class 1, AWG 18, length as required.

Group 5-7, 9, Configuration 3:

None.

2. Parts and Materials Supplied by the Operator:

The following parts or materials are necessary to do the change in this service bulletin. Parts and

materials in the manuals given in Paragraph 1.J., References, can also be necessary. Examine

operator part and material supply to make sure all necessary parts and materials are available.

Group 1, 8:

Operators with Group 1 and Group 8 airplanes should contact The Boeing Company to get

engineering and accomplishment instructions for this change and do the instructions.

Group 2-4, 9-13:

Part Number / Specification QTY Name Notes

ALODINE As Necessary Chemical Conversion Coating (a)

BMS 10-11, TYPE 1 As Necessary Epoxy Primer (b)

(a) Refer to SOPM 20-43-03 for application procedure, specification and material sources of Chemical

Conversion Coating.

(b) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data.

Group 5-7, 9:

Part Number / Specification QTY Name Notes

ALODINE As Necessary Chemical Conversion Coating (a)

BMS 10-11, TYPE 1 As Necessary Epoxy Primer (b)

Replaces BMS 3-2.

(b)

TT-N-95 or equivalent As Necessary Naphtha, Aliphatic

Dymo 358 (3M 425 optional) 6 inches Tape

(a) Refer to SOPM 20-43-03 for application procedure, specification and material sources of Chemical

Conversion Coating.

(b) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data.

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ALERT ALERT
Group 2, Configuration 1:

Part Number / Specification QTY Name Existing Part Number Notes

Ground Fault Interrupter (GFI) 10-60450-1 (b) (a)

Relay

S283A004-1 (LEACH P/N 6

9524G-10674)

(a) Leach International North America (V58657) 6900 Orangethorpe Avenue, P.O. Box 5032 Buena Park,

CA 90622-5032 Phone: (714) 739-0770, FAX: (714) 670-1145.

(b) Keep the existing part if there are other uses for it.

Group 3, 10-13, Configuration 1:

Part Number / Specification QTY Name Existing Part Number Notes

Ground Fault Interrupter (GFI) 10-60450-6 (c) (a) (b)

Relay

S283A004-1 (LEACH P/N 8

9524G-10674)

(a) Leach International North America (V58657) 6900 Orangethorpe Avenue, P.O. Box 5032 Buena Park,

CA 90622-5032 Phone: (714) 739-0770, FAX: (714) 670-1145.

(b) Airplanes in Group 12 and 13 have been delivered with wire provisions for Auxiliary Tank installation.

If Auxiliary Tanks have not been installed on these airplanes there are more parts than necessary

given in this table. Operators only need to obtain the necessary parts to incorporate this service bulletin.

(c) Keep the existing part if there are other uses for it.

Group 4, Configuration 1:

Part Number / Specification QTY Name Existing Part Number Notes

Ground Fault Interrupter (GFI) KCD4N (b) (a)

Relay

S283A004-6 (LEACH P/N KCG- 6

X4L-001)

002-9667-001-000 6 Relay Installation Kit - (a)

(a) Leach International North America (V58657) 6900 Orangethorpe Avenue, P.O. Box 5032 Buena Park,

CA 90622-5032 Phone: (714) 739-0770, FAX: (714) 670-1145

(b) Keep the existing part if there are other uses for it.

Group 5, Configuration 1:

Part Number / Specification QTY Name Existing Part Number Notes

Ground Fault Interrupter (GFI) 10-60450-6 (b) (a)

Relay

S283A004-1 (LEACH P/N 2

9524G-10674)

Ground Fault Interrupter (GFI) KCD4N (b) (a)

Relay

S283A004-6 (LEACH P/N KCG- 4

X4L-001)

002-9667-001-000 4 Relay Installation Kit - (a)

(a) Leach International North America (V58657) 6900 Orangethorpe Avenue, P.O. Box 5032 Buena Park,

CA 90622-5032 Phone: (714) 739-0770, FAX: (714) 670-1145

(b) Keep the existing part if there are other uses for it.

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ALERT ALERT
Group 6, Configuration 1:

Part Number / Specification QTY Name Existing Part Number Notes

Ground Fault Interrupter (GFI) 10-60450-6 (b) (a)

Relay

S283A004-1 (LEACH P/N 4

9524G-10674)

Ground Fault Interrupter (GFI) KCD4N (b) (a)

Relay

S283A004-6 (LEACH P/N KCG- 4

X4L-001)

002-9667-001-000 4 Relay Installation Kit - (a)

(a) Leach International North America (V58657) 6900 Orangethorpe Avenue, P.O. Box 5032 Buena Park,

CA 90622-5032 Phone: (714) 739-0770, FAX: (714) 670-1145

(b) Keep the existing part if there are other uses for it.

Group 7, 9, Configuration 1:

Part Number / Specification QTY Name Existing Part Number Notes

Ground Fault Interrupter (GFI) 10-60450-6 (b) (a)

Relay

S283A004-1 (LEACH P/N 2

9524G-10674)

Ground Fault Interrupter (GFI) KCD4N (b) (a)

Relay

S283A004-6 (LEACH P/N KCG- 6

X4L-001)

002-9667-001-000 6 Relay Installation Kit - (a)

(a) Leach International North America (V58657) 6900 Orangethorpe Avenue, P.O. Box 5032 Buena Park,

CA 90622-5032 Phone: (714) 739-0770, FAX: (714) 670-1145

(b) Keep the existing part if there are other uses for it.

3. Parts Modified and Reidentified:

Group 1, 8:

Operators with Group 1 and Group 8 airplanes should contact The Boeing Company to get

engineering and accomplishment instructions for this change and do the instructions.

Group 2-7, 9-13:

None.

4. Parts Removed and Not Replaced:

None.

D. Parts Necessary to Change Spares

None.

E. Special Tooling - Price and Availability

None.

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BOEING SERVICE BULLETIN 737-28A1212

ALERT ALERT
F. Special Tooling Necessary to do this Service Bulletin

No special tools or equipment are necessary to do the change in this service bulletin. But, maintenance

and overhaul tools in the manuals given in Paragraph 1.J., References, can be necessary. Examine

operator tool supply to make sure all necessary tools are available.

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BOEING SERVICE BULLETIN 737-28A1212

ALERT ALERT
3. ACCOMPLISHMENT INSTRUCTIONS

A. GENERAL INFORMATION

CAUTION: KEEP THE WORK AREA, WIRES AND ELECTRICAL BUNDLES CLEAN OF METAL

PARTICLES OR CONTAMINATION WHEN YOU USE TOOLS. UNWANTED MATERIAL,

METAL PARTICLES OR CONTAMINATION CAUGHT IN WIRE BUNDLES CAN CAUSE

DAMAGE TO THE BUNDLES. DAMAGED WIRE BUNDLES CAN CAUSE SPARKS OR

OTHER ELECTRICAL DAMAGE.

NOTE: 1. Manual titles are referred to by acronyms. Refer to Paragraph 1.J., References, for

definition of the acronyms.

2. Obey all of the warnings and cautions given in the specified manual sections.

3. Unless shown differently, these dimensions and tolerances are used:

– Linear dimensions are in inches

– Tolerance on linear dimensions, other than rivet and bolt edge margins, is plus

or minus 0.03 inch

– Tolerance on rivet and bolt edge margin is plus or minus 0.05 inch

– Angular tolerance is plus or minus 2 degrees

– Hole dimensions for standard solid rivets are in Structural Repair Manual (SRM)

51

– Torque limits to tighten nuts and bolts are in SRM 51

4. Use the approved fastener and process material substitutions in accordance with

SRM Chapter 51.

5. Refer to the SWPM 20-10-11 and SWPM 20-10-12 for the wire installation procedures,

and SWPM 20-10-19 for the wire separation requirements, as accepted procedures.

6. If the length of any fastener specified in this service bulletin does not meet installation

standards given in SRM Chapter 51, then a fastener of the same specification, or

an approved substitute, with a length which meets the installation standards given

in SRM Chapter 51 may be used. In addition, washers may be installed for fastener

grip length in accordance with SRM Chapter 51.

7. These work instructions refer to procedures included in other Boeing documents.

When the words "refer to" are used and the operator has an accepted alternative

procedure, the accepted alternative procedure can be used. When the words "in

accordance with" are included in the instruction, the procedure in the Boeing document

must be used.

8. The instructions in Paragraph 3.B., Work Instructions and the figures can include

operation of tools or test equipment. Boeing Engineering Tool Drawings, the Illustrated

Tool and Equipment Manual, and the Special Tool and Ground Handling Drawing

Index contain data on versions of the tools or test equipment that you can use. It is

permitted to use replaced tools. It is not permitted to use superseded tools.

9. If it is necessary to remove more parts for access, you can remove those parts. If

you can get access without removing identified parts, it is not necessary to remove

all of the identified parts. Jacking and shoring limitations must be observed.

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ALERT ALERT
10. Where the work instructions include installation of a kept part, a new or serviceable

part with the same part number can be installed as an alternative to the kept part.

The removed part can be discarded if a new or serviceable part is installed.

11. This service bulletin includes functional test procedures for the systems changed or

modified by this service bulletin. More functional tests can possibly be necessary in

accordance with standard maintenance practices because of interruption to other

airplane systems.

B. WORK INSTRUCTIONS

Group 2-7, 9-13, Configuration 1:

PART 1 - GROUND STUDS AND BONDING JUMPER INSTALLATION AND FUEL BOOST PUMP

RELAYS REPLACEMENT

1. Remove the electrical power from the airplane. Refer to 737-100/200 AMM 24-22-00 or

737-300/400/500 AMM 24-22-00 as an accepted procedure.

2. Get access to the flight compartment.

3. In the flight compartment, move the First Officer's seat forward to create room in front of P6 Load

Control Panel. Refer to 737-100/200 AMM 25-11-0 or 737-300/400/500 AMM 25-11-11 as an

accepted procedure. If necessary remove the First Officer's seat. Refer to 737-100/200 AMM

25-11-11 or 737-300/400/500 AMM 25-11-11 as an accepted procedure.

4. In the flight compartment, remove and keep the adjacent lining panels outboard of the P6-2 circuit

breaker panel. Refer to 737-100/200 AMM 25-16-11 or 737-300/400/500 AMM 25-11-21 as an

accepted procedure.

5. Open and lower the P6-1 (65C25704-( ) ) and P6-2 (65C25704-( ) ) panels.

6. Group 2-7, 9-13, Configuration 1:

Install Ground Studs and Bonding Jumper and measure the electrical bonding resistance between

P6-2 relay panel and the P6 side panel in accordance with FIGURE 22.

7. Group 2, Configuration 1:

Replace the fuel pump power relays R18, R19, R20, R21, R54, and R55 and measure the electrical

bonding between each new relay and P6-2 relay panel in accordance with FIGURE 2.

8. Group 3, 10-13, Configuration 1:

Replace the fuel pump power relays R18, R19, R20, R21, R54, R55, R146, and R147 and measure

the electrical bonding between each new relay and P6-2 relay panel in accordance with FIGURE

3.

9. Group 4, Configuration 1:

Replace the fuel pump power relays R18, R19, R20, R21, R54, and R55 and measure the electrical

bonding between each new relay and P6-2 relay panel in accordance with FIGURE 4.

10. Group 5, Configuration 1:

Replace the fuel pump power relays R18, R19, R20, R21, R54, and R55, install R18 and R19

turned 180 degrees from their original position, then measure the electrical bonding between each

new relay and P6-2 relay panel in accordance with FIGURE 5.

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ALERT ALERT
11. Group 6, Configuration 1:

Replace the fuel pump power relays R18, R19, R20, R21, R54, R55, R146, and R147, install R146

and R147 turned 180 degrees from their original position, then measure the electrical bonding

between each new relay and P6-2 relay panel in accordance with FIGURE 6.

12. Group 7, 9, Configuration 1:

Replace the fuel pump power relays R18, R19, R20, R21, R54, R55, R146, and R147, install R146

and R147 turned 180 degrees from their original position, then measure the electrical bonding

between each new relay and P6-2 relay panel in accordance with FIGURE 7.

13. Group 2-3, 6-7, 9-13, Configuration 1:

Remove the galley number one to get access to the W0044 wire bundle in the P6 panel. Refer to

737-100/200 AMM 25-31-11 or 737-300/400/500 AMM 25-31-11 as an accepted procedure.

14. Group 2, Configuration 1:

Change the W0044 wire bundle in accordance with FIGURE 8, FIGURE 9, and FIGURE 20.

15. Group 3, 12, Configuration 1:

Change the W0044 wire bundle in accordance with FIGURE 8, FIGURE 10, and FIGURE 20.

16. Group 6-7, 9, Configuration 1:

Change the W0044 wire bundle in accordance with FIGURE 8, FIGURE 11, and FIGURE 20.

17. Group 10, Configuration 1:

Change the W0044 wire bundle in accordance with FIGURE 8, FIGURE 12, and FIGURE 20.

18. Group 11, 13, Configuration 1:

Change the W0044 wire bundle in accordance with FIGURE 8, FIGURE 13, and FIGURE 20.

19. Group 2-3, 6-7, 9-13, Configuration 1:

Install the galley number one. Refer to 737-100/200 AMM 25-31-11 or 737-300/400/500 AMM

25-31-11 as an accepted procedure.

20. In the flight compartment, install the adjacent lining panels outboard of the P6-2 circuit breaker

panel. Refer to 737-100/200 AMM 25-16-11 or 737-300/400/500 AMM 25-11-21 as an accepted

procedure.

21. Close the P6-1 (65C25704-( ) ) and P6-2 (65C25704-( ) ) panels.

22. Restore the position of the First Officer's seat if it was moved forward to create room in front of P6

Load Control Panel. Refer to 737-100/200 AMM 25-11-0 or 737-300/400/500 AMM 25-11-11 as

an accepted procedure. If the First Officer's seat was removed, install the First Officer's seat. Refer

to 737-100/200 AMM 25-11-11 or 737-300/400/500 AMM 25-11-11 as an accepted procedure.

23. Supply electrical power to the airplane. Refer to 737-100/200 AMM 24-22-00 or 737-300/400/500

AMM 24-22-00 as an accepted procedure.

24. Do the "GROUND FAULT INTERRUPTER (GFI) - OPERATIONAL TEST". Refer, as applicable,

to 737-100/200 AMM 28-22-41 or 737-300/400/500 AMM 28-22-41 as an accepted procedure.

25. Put the airplane back to a serviceable condition.

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BOEING SERVICE BULLETIN 737-28A1212

ALERT ALERT
Group 2-7, 9-13, Configuration 2:

PART 2 - GROUND STUDS AND BONDING JUMPER INSTALLATION AND GFI RELAY POSITION

CHANGE - MORE WORK FOR AIRPLANES THAT HAVE BEEN CHANGED IN ACCORDANCE

WITH THE ORIGINAL ISSUE OF THIS SERVICE BULLETIN.

1. Remove the electrical power from the airplane. Refer to 737-100/200 AMM 24-22-00 or

737-300/400/500 AMM 24-22-00 as an accepted procedure.

2. Get access to the flight compartment.

3. Install Ground Studs and Bonding Jumper in accordance with FIGURE 22.

4. Group 5-7, 9, Configuration 2:

Remove and keep two GFI relays on the P6-2 relay panel, turn the relay sockets 180 degrees

then install the kept relays in the new position as follows:

a. Group 5, Configuration 2:

R18 and R19 in accordance with FIGURE 23.

b. Group 6, Configuration 2:

R146 and R147 in accordance with FIGURE 24.

c. Group 7, 9, Configuration 2:

R146 and R147 in accordance with FIGURE 25.

5. Supply electrical power to the airplane. Refer to 737-100/200 AMM 24-22-00 or 737-300/400/500

AMM 24-22-00 as an accepted procedure.

6. Do the "GROUND FAULT INTERRUPTER (GFI) - OPERATIONAL TEST" on all GFI relays. Refer

to 737-100/200 AMM 28-22-41 or 737-300/400/500 AMM 28-22-41 as an accepted procedure.

a. If any of the GFI relays fail the "GROUND FAULT INTERRUPTER (GFI) - OPERATIONAL

TEST", make sure that the bonding resistance between the GFI relay flange and the mounting

panel is 0.0025 Ohms (2.5 milliohms) or less, in accordance with APPENDIX A, Paragraph

5.b.

(1) If the resistance measurement is greater than 0.0025 Ohms (2.5 milliohms), then remove

the relay, clean the faying surfaces, install the relay again and measure the bonding

resistance, in accordance with APPENDIX A.

(2) If the resistance measurement is 0.0025 Ohms (2.5 milliohms) or less replace the GFI

relay. Refer to 737-100/200 AMM 28-22-18 or 737-300/400/500 AMM 28-22-18 as an

accepted procedure.

(3) Repeat the "GROUND FAULT INTERRUPTER (GFI) - OPERATIONAL TEST". Refer to

737-100/200 AMM 28-22-41 or 737-300/400/500 AMM 28-22-41 as an accepted procedure.

7. Put the airplane back to a serviceable condition.

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ALERT ALERT
Group 1, 8:

PART 3 - THIS PART IS DELETED

1. Operators with Group 1 and Group 8 airplanes should contact The Boeing Company to get

engineering and accomplishment instructions for this change and do the instructions.

Group 5-7, 9, Configuration 3:

PART 4 - GFI RELAY POSITION CHANGE - MORE WORK FOR AIRPLANES THAT HAVE BEEN

CHANGED IN ACCORDANCE WITH REVISION 1 OF THIS SERVICE BULLETIN

1. Remove the electrical power from the airplane. Refer to 737-100/200 AMM 24-22-00 or

737-300/400/500 AMM 24-22-00 as an accepted procedure.

2. Get access to the flight compartment.

3. Remove and keep two GFI relays on the P6-2 relay panel, turn the relay sockets 180 degrees

then install the kept relays in the new position as follows:

a. Group 5, Configuration 3:

R18 and R19 in accordance with FIGURE 23.

b. Group 6, Configuration 3:

R146 and R147 in accordance with FIGURE 24.

c. Group 7, 9, Configuration 3:

R146 and R147 in accordance with FIGURE 25.

4. Supply electrical power to the airplane. Refer to 737-100/200 AMM 24-22-00 or 737-300/400/500

AMM 24-22-00 as an accepted procedure.

5. Do the "GROUND FAULT INTERRUPTER (GFI) - OPERATIONAL TEST" on all GFI relays. Refer

to 737-100/200 AMM 28-22-41 or 737-300/400/500 AMM 28-22-41 as an accepted procedure.

a. If any of the GFI relays fail the "GROUND FAULT INTERRUPTER (GFI) - OPERATIONAL

TEST", make sure that the bonding resistance between the GFI relay flange and the mounting

panel is 0.0025 Ohms (2.5 milliohms) or less, in accordance with APPENDIX A, Paragraph

5.b.

(1) If the resistance measurement is greater than 0.0025 Ohms (2.5 milliohms), then remove

the relay, clean the faying surfaces, install the relay again and measure the bonding

resistance, in accordance with APPENDIX A.

(2) If the resistance measurement is 0.0025 Ohms (2.5 milliohms) or less replace the GFI

relay. Refer to 737-100/200 AMM 28-22-18 or 737-300/400/500 AMM 28-22-18 as an

accepted procedure.

(3) Repeat the "GROUND FAULT INTERRUPTER (GFI) - OPERATIONAL TEST". Refer to

737-100/200 AMM 28-22-41 or 737-300/400/500 AMM 28-22-41 as an accepted procedure.

6. Put the airplane back to a serviceable condition.

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BOEING SERVICE BULLETIN 737-28A1212

ALERT ALERT
This Figure applies only to: Group 1, 8.

FIGURE 1: M181, M182, M183 RELAY MODULE ASSEMBLY - REPLACEMENT

(SHEET 1 OF 1)

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ALERT ALERT
This Figure applies only to: Group 2, Configuration 1.

FIGURE 2: P6-2 RELAY PANEL - FUEL PUMP POWER RELAY - REPLACEMENT

(SHEET 1 OF 2)

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BOEING SERVICE BULLETIN 737-28A1212

ALERT ALERT
The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY

numbers shown below are the number of parts necessary for each airplane.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

R18, R19, R20, R21,

R54, and R55.

1 Remove Fuel Pump Power Relay 10-60450-1 6

Remove the paint

around the relay

cutout, from the side

of the panel that will

be in contact with the

relay. (a)

2 Clean Surface - -

On the bare surfaces.

Refer to SOPM 20-43-

03 as an accepted

procedure.

3 Apply Chemical Conversion Coating ALODINE -

The contact surfaces

of the relay and the

panel to remove contamination. (b)

4 Clean Surface - -

R18, R19, R20, R21,

R54, and R55. Refer

to SWPM 20-81-22 as

an accepted procedure for installation of

similar LEACH relays.

S283A004-1 6

(LEACH P/N

9524G-10674)

Install / Fuel Pump Power (GFI) Relay

New

5

Between the flange of

the relay and the

mounting panel. (c)

0.0025 OHMS (2.5 6

MILLIOHMS)

6 Measure Resistance

On any bare metal

around the relays. Refer to SOPM 20-41-02

as an accepted procedure.

BMS 10-11, TYPE -

1

7 Apply Epoxy Primer

(a) Abrasive clean by Hand or with a rotary brush in accordance with APPENDIX A, Paragraph 2.a.

(b) Use Solvent to clean the contact surfaces in accordance with APPENDIX A, Paragraph 2.b.

(c) Make sure that the resistance is 2.5 milliohms or less in accordance with APPENDIX A, Paragraph

5.b. If the resistance measurement is greater than 0.0025 Ohms (2.5 milliohms), then remove the

relay, clean the faying surfaces, install the relay and measure the bonding resistance again.

FIGURE 2: P6-2 RELAY PANEL - FUEL PUMP POWER RELAY - REPLACEMENT

(SHEET 2 OF 2)

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BOEING SERVICE BULLETIN 737-28A1212

ALERT ALERT
This Figure applies only to: Group 3, 10-13, Configuration 1.

FIGURE 3: P6-2 RELAY PANEL - FUEL PUMP POWER RELAY - REPLACEMENT

(SHEET 1 OF 2)

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61 of 123

BOEING SERVICE BULLETIN 737-28A1212

ALERT ALERT
The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY

numbers shown below are the number of parts necessary for each airplane.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

R18, R19, R20, R21, R54,

R55, R146, and R147.

1 Remove Fuel Pump Power Relay 10-60450-6 8

Remove the paint around

the relay cutout, from the

side of the panel that will be

in contact with the relay. (a)

2 Clean Surface - -

On the bare surfaces. Refer

to SOPM 20-43-03 as an

accepted procedure.

3 Apply Chemical Conversion Coating ALODINE -

The contact surfaces of the

relays and the panel to remove contamination. (b)

4 Clean Surface - -

R18, R19, R20, R21, R54,

R55, R146, and R147. Refer to SWPM 20-81-22 as

an accepted procedure for

installation of similar

LEACH relays. (d)

S283A004-1 8

(LEACH P/N

9524G-10674)

Install / Fuel Pump Power (GFI) Relay

New

5

Between the flange of the

relay and the mounting

panel. (c)

0.0025 OHMS (2.5 8

MILLIOHMS)

6 Measure Resistance

On any bare metal around

the relays. Refer to SOPM

20-41-02 as an accepted

procedure.

BMS 10-11, TYPE -

1

7 Apply Epoxy Primer

(a) Abrasive clean by Hand or with a rotary brush in accordance with APPENDIX A, Paragraph 2.a.

(b) Use Solvent to clean the contact surfaces in accordance with APPENDIX A, Paragraph 2.b.

(c) Make sure that the resistance is 2.5 milliohms or less in accordance with APPENDIX A, Paragraph

5.b. If the resistance measurement is greater than 0.0025 Ohms (2.5 milliohms), then remove the relay,

clean the faying surfaces, install the relay and measure the bonding resistance again.

(d) Airplanes in Group 12 and 13 have been delivered with wire provisions for Auxiliary Tanks installation.

If Auxiliary Tanks have been installed on these airplanes operators need to order this kit. If Auxiliary

Tanks have not been installed on these airplanes there are more parts than necessary in this kit. Operators need to obtain only the necessary parts to incorporate this service bulletin for Tank 1, Tank 2,

and Center Tank.

FIGURE 3: P6-2 RELAY PANEL - FUEL PUMP POWER RELAY - REPLACEMENT

(SHEET 2 OF 2)

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BOEING SERVICE BULLETIN 737-28A1212

ALERT ALERT
This Figure applies only to: Group 4, Configuration 1.

FIGURE 4: P6-2 RELAY PANEL - FUEL PUMP POWER RELAY - REPLACEMENT

(SHEET 1 OF 2)

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BOEING SERVICE BULLETIN 737-28A1212

ALERT ALERT
The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY

numbers shown below are the number of parts necessary for each airplane.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

R18, R19, R20, R21,

R54, and R55.

1 Remove Fuel Pump Power Relay KCD4N 6

Remove the paint from

both sides of the panel

that will be in contact with

the relay spacers and

spacer hardware. (a)

2 Clean Surface - -

On the bare surfaces.

Refer to SOPM 20-43-03

as an accepted procedure.

3 Apply Chemical Conversion Coating ALODINE -

The contact surfaces of

the relays, spacers, and

the panel, to remove contamination. (b)

4 Clean Surface - -

R18, R19, R20, R21,

R54, and R55. Refer to

SWPM 20-81-22 as an

accepted procedure for

installation of similar

LEACH relays.

S283A004-6 6

(LEACH P/N KCGX4L-001)

Install / Fuel Pump Power (GFI) Relay

New

5

Relay Spacer Kit 002-9667-001-000 6

Between the flange of the

relay and the mounting

panel. (c)

0.0025 OHMS (2.5 6

MILLIOHMS)

6 Measure Resistance

On any bare metal

around spacers. Refer to

SOPM 20-41-02 as an

accepted procedure.

BMS 10-11, TYPE -

1

7 Apply Epoxy Primer

(a) Abrasive clean by Hand or with a rotary brush in accordance with APPENDIX A, Paragraph 2.a.

(b) Use Solvent to clean the contact surfaces in accordance with APPENDIX A, Paragraph 2.b..

(c) Make sure that the resistance is 2.5 milliohms or less in accordance with APPENDIX A, Paragraph 5.b.

If the resistance measurement is greater than 0.0025 Ohms (2.5 milliohms), then remove the relay,

clean the faying surfaces, install the relay and measure the bonding resistance again.

FIGURE 4: P6-2 RELAY PANEL - FUEL PUMP POWER RELAY - REPLACEMENT

(SHEET 2 OF 2)

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BOEING SERVICE BULLETIN 737-28A1212

ALERT ALERT
This Figure applies only to: Group 5, Configuration 1.

FIGURE 5: P6-2 RELAY PANEL - FUEL PUMP POWER RELAY - REPLACEMENT

(SHEET 1 OF 6)

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BOEING SERVICE BULLETIN 737-28A1212

ALERT ALERT
FIGURE 5: P6-2 RELAY PANEL - FUEL PUMP POWER RELAY - REPLACEMENT

(SHEET 2 OF 6)

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BOEING SERVICE BULLETIN 737-28A1212

ALERT ALERT
FIGURE 5: P6-2 RELAY PANEL - FUEL PUMP POWER RELAY - REPLACEMENT

(SHEET 3 OF 6)

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67 of 123

BOEING SERVICE BULLETIN 737-28A1212

ALERT ALERT
The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY

numbers shown below are the number of parts necessary for each airplane.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Remove Fuel Pump Power Relay KCD4N 4 R20, R21, R54, and R55.

2 Remove Fuel Pump Power Relay 10-60450-6 2 R18 and R19.

For R18 and R19 and related hardware.Remove / Fuel Pump Power Relay Socket 10-60450-5 2

Keep

3

Diameter 0.151 to 0.161

inch. (d) (e)

4 Drill Holes - 6

Remove the paint from

both sides of the panel that

will be in contact with the

relay spacers and spacer

hardware. (a)

5 Clean Surface - -

Remove the paint around

the relay cutout, from the

side of the panel that will

be in contact with the relay. (a)

6 Clean Surface - -

On the bare surfaces. Refer to SOPM 20-43-03 as

an accepted procedure.

7 Apply Chemical Conversion Coating ALODINE -

Approximately as shown.

Use Dymo 358 Aluminium

tape or equivalent. (h)

8 Make Decal - 1

To prepare to install the

Decal and tape to cover

holes. Use TT-N-95 or

equivalent. Do not allow to

evaporate, but wipe dry

with a clean cloth.

9 Clean Surface - -

Remove the backing and

install the Decal and tape

on the P6-2 panel. Take

care not to contaminate

the adhesive and make

sure the tape has sufficient

clearance to avoid contact

with the new relay spacers

and does not overlap the

relay cut-out. (i)

DYMO 358 (3M 5

425 optional)

10 Install Tape and Decal

FIGURE 5: P6-2 RELAY PANEL - FUEL PUMP POWER RELAY - REPLACEMENT

(SHEET 4 OF 6)

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BOEING SERVICE BULLETIN 737-28A1212

ALERT ALERT
STEP TASK NAME IDENTIFICATION QTY MORE DATA

The contact surfaces of

the relays, spacers, and

the panel, to remove contamination. (b)

11 Clean Surface - -

R20, R21, R54, and R55.

Refer to SWPM 20-81-22

as an accepted procedure

for installation of similar

LEACH relays.

S283A004-6 4

(LEACH P/N KCGX4L-001)

Install / Fuel Pump Power (GFI)

New

12

Relay Spacer Kit 002-9667-001-000 4

For R18 and R19, and related hardware, turned 180

degrees. Refer to SWPM

20-81-22 as an accepted

procedure. (f)

Install / Fuel Pump Power Relay Socket 10-60450-5 2

Kept

13

R18 and R19 in the

changed sockets. Refer to

SWPM 20-81-22 as an accepted procedure for installation of similar LEACH relays. (g)

S283A004-1 2

(LEACH P/N

9524G-10674)

Install / Fuel Pump Power (GFI) Relay

New

14

Between the flange of the

relay and the mounting

panel. (c)

0.0025 OHMS (2.5 6

MILLIOHMS)

15 Measure Resistance

On any bare metal around

the relays and spacers and

plugs. Refer to SOPM 20-

41-02 as an accepted procedure.

BMS 10-11, TYPE -

1

16 Apply Epoxy Primer

(a) Abrasive clean by Hand or with a rotary brush in accordance with APPENDIX A, Paragraph 2.a.

(b) Use Solvent to clean the contact surfaces in accordance with APPENDIX A, Paragraph 2.b.

(c) Make sure that the resistance is 2.5 milliohms or less in accordance with APPENDIX A, Paragraph 5.b.

If the resistance measurement is more than 0.0025 Ohms (2.5 milliohms), remove the relay, clean the

faying surfaces, install the relay and measure the bonding resistance again.

(d) Use the Fuel Pump Power (GFI) Relay, LEACH P/N 9524G-10674, as a template to mark the new holes.

Put the relay into the existing cutout, turned 180 degrees from its original position, then mark and drill

the new holes.

(e) It is not necessary to change the size or shape of the cut-out in the relay panel. The existing cut-out is

acceptable to allow installation of relay turned 180 degrees.

(f) Use the new holes for installation. The original holes are not used.

(g) Install the existing connectors for R18 and R19 turned 180 degrees to agree with the changed sockets.

Adjust wire bundles if necessary. Refer to SWPM 20-10-11 and SWPM 20-10-12, as accepted procedures.

FIGURE 5: P6-2 RELAY PANEL - FUEL PUMP POWER RELAY - REPLACEMENT

(SHEET 5 OF 6)

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BOEING SERVICE BULLETIN 737-28A1212

ALERT ALERT
STEP TASK NAME IDENTIFICATION QTY MORE DATA

(h) Use Dymo M11 Tapewriter or equivalent to emboss the Decal. Use one, two or three pieces of tape, as

necessary, for the decal. Trim the tape and decal, as necessary, to fit the locations shown in Detail A -

AFTER.

(i) Install the decal at the approximate location shown.

FIGURE 5: P6-2 RELAY PANEL - FUEL PUMP POWER RELAY - REPLACEMENT

(SHEET 6 OF 6)

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BOEING SERVICE BULLETIN 737-28A1212

ALERT ALERT
This Figure applies only to: Group 6, Configuration 1.

FIGURE 6: P6-2 RELAY PANEL - FUEL PUMP POWER RELAY - REPLACEMENT

(SHEET 1 OF 5)

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ALERT ALERT
FIGURE 6: P6-2 RELAY PANEL - FUEL PUMP POWER RELAY - REPLACEMENT

(SHEET 2 OF 5)

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BOEING SERVICE BULLETIN 737-28A1212

ALERT ALERT
FIGURE 6: P6-2 RELAY PANEL - FUEL PUMP POWER RELAY - REPLACEMENT

(SHEET 3 OF 5)

Export Controlled ECCN: 9E991 - BOEING

PROPRIETARY - Copyright © Unpublished

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73 of 123

BOEING SERVICE BULLETIN 737-28A1212

ALERT ALERT
The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY

numbers shown below are the number of parts necessary for each airplane.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Remove Fuel Pump Power Relay KCD4N 4 R20, R21, R54, and R55.

2 Remove Fuel Pump Power Relay 10-60450-6 4 R146, R147, R18, and R19.

For R146 and R147 and related hardware.Fuel Pump Power Relay Sock- 10-60450-5 2

et

Remove /

Keep

3

Diameter 0.151 to 0.161 inch.

(d) (e)

4 Drill Holes - 6

Remove the paint from both

sides of the panel that will be

in contact with the relay

spacers and spacer hardware. (a)

5 Clean Surface - -

Remove the paint around the

relay cutout, from the side of

the panel that will be in contact with the relay. (a)

6 Clean Surface - -

On the bare surfaces. Refer

to SOPM 20-43-03 as an accepted procedure.

7 Apply Chemical Conversion Coating ALODINE -

Approximately as shown. Use

Dymo 358 Aluminium tape or

equivalent. (h)

8 Make Decal - 1

To prepare to install the Decal

and tape to cover holes. Use

TT-N-95 or equivalent. Do not

allow to evaporate, but wipe

dry with a clean cloth.

9 Clean Surface - -

Remove the backing and install the Decal and tape on

the P6-2 panel. Take care not

to contaminate the adhesive

and make sure the tape has

sufficient clearance to avoid

contact with the new relay

spacers and does not overlap

the relay cut-out. (i)

DYMO 358 (3M 5

425 optional)

10 Apply Tape and Decal

The contact surfaces of the

relays, spacers, and the panel, to remove contamination.

(b)

11 Clean Surface - -

FIGURE 6: P6-2 RELAY PANEL - FUEL PUMP POWER RELAY - REPLACEMENT

(SHEET 4 OF 5)

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BOEING SERVICE BULLETIN 737-28A1212

ALERT ALERT
STEP TASK NAME IDENTIFICATION QTY MORE DATA

R20, R21, R54, and R55. Refer to SWPM 20-81-22 as an

accepted procedure for installation of similar LEACH relays.

S283A004-6 4

(LEACH P/N KCGX4L-001)

Install / Fuel Pump Power (GFI)

New

12

Relay Spacer Kit 002-9667-001-000 4

For R146 and R147, and related hardware, turned 180 degrees. Refer to SWPM 20-81-

22 as an accepted procedure.

(f)

Fuel Pump Power Relay Sock- 10-60450-5 1

et

Install /

Kept

13

R146, R147, R18, and R19.

Refer to SWPM 20-81-22 as

an accepted procedure for installation of similar LEACH

relays. (g)

S283A004-1 4

(LEACH P/N

9524G-10674)

Install / Fuel Pump Power (GFI) Relay

New

14

Between the flange of the relay and the mounting panel.

(c)

0.0025 OHMS (2.5 8

MILLIOHMS)

15 Measure Resistance

On any bare metal around the

relays and spacers. Refer to

SOPM 20-41-02 as an accepted procedure.

BMS 10-11, TYPE -

1

16 Apply Epoxy Primer

(a) Abrasive clean by Hand or with a rotary brush in accordance with APPENDIX A, Paragraph 2.a.

(b) Use Solvent to clean the contact surfaces in accordance with APPENDIX A, Paragraph 2.b.

(c) Make sure that the resistance is 2.5 milliohms or less in accordance with APPENDIX A, Paragraph 5.b.

If the resistance measurement is more than 0.0025 Ohms (2.5 milliohms), remove the relay, clean the

faying surfaces, install the relay and measure the bonding resistance again.

(d) Use the Fuel Pump Power (GFI) Relay, LEACH P/N 9524G-10674, as a template to mark the new holes.

Put the relay into the existing cutout, turned 180 degrees from its original position, then mark and drill the

new holes.

(e) It is not necessary to change the size or shape of the cut-out in the relay panel. The existing cut-out is

acceptable to allow installation of relay turned 180 degrees.

(f) Use the new holes for installation. The original holes are not used.

(g) Install the existing connectors for R146 and R147 turned 180 degrees to agree with the changed sockets.

Adjust wire bundles if necessary. Refer to SWPM 20-10-11 and SWPM 20-10-12, as accepted procedures.

(h) Use Dymo M11 Tapewriter or equivalent to emboss the Decal. Use one, two or three pieces of tape, as

necessary, for the decal. Trim the tape and decal, as necessary, to fit the locations shown in Detail A -

AFTER.

(i) Install the decal at the approximate location shown.

FIGURE 6: P6-2 RELAY PANEL - FUEL PUMP POWER RELAY - REPLACEMENT

(SHEET 5 OF 5)

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BOEING SERVICE BULLETIN 737-28A1212

ALERT ALERT
This Figure applies only to: Group 7, 9, Configuration 1.

FIGURE 7: P6-2 RELAY PANEL - FUEL PUMP POWER RELAY - REPLACEMENT

(SHEET 1 OF 6)

Export Controlled ECCN: 9E991 - BOEING

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BOEING SERVICE BULLETIN 737-28A1212

ALERT ALERT
FIGURE 7: P6-2 RELAY PANEL - FUEL PUMP POWER RELAY - REPLACEMENT

(SHEET 2 OF 6)

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BOEING SERVICE BULLETIN 737-28A1212

ALERT ALERT
FIGURE 7: P6-2 RELAY PANEL - FUEL PUMP POWER RELAY - REPLACEMENT

(SHEET 3 OF 6)

Export Controlled ECCN: 9E991 - BOEING

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78 of 123

BOEING SERVICE BULLETIN 737-28A1212

ALERT ALERT
The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY

numbers shown below are the number of parts necessary for each airplane.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

R18, R19, R20, R21,

R54, and R55.

Fuel Pump Power KCD4N 6

Relay

1 Remove

Fuel Pump Power 10-60450-6 2 R146 and R147.

Relay

2 Remove

For R146 and R147 and

related hardware.

Fuel Pump Power 10-60450-5 2

Relay Socket

3 Remove / Keep

Diameter 0.151 to 0.161

inch. (d) (e)

4 Drill Holes - 6

Remove the paint from

both sides of the panel

that will be in contact with

the relay spacers and

spacer hardware. (a)

5 Clean Surface - -

Remove the paint around

the relay cutout, from the

side of the panel that will

be in contact with the relay. (a)

6 Clean Surface - -

On the bare surfaces.

Refer to SOPM 20-43-03

as an accepted procedure.

Chemical Conver- ALODINE -

sion Coating

7 Apply

Approximately as shown.

Use Dymo 358 Aluminium

tape or equivalent. (h)

8 Make Decal - 1

To prepare to install the

Decal and tape to cover

holes. Use TT-N-95 or

equivalent. Do not allow

to evaporate, but wipe dry

with a clean cloth.

9 Clean Surface - -

FIGURE 7: P6-2 RELAY PANEL - FUEL PUMP POWER RELAY - REPLACEMENT

(SHEET 4 OF 6)

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BOEING SERVICE BULLETIN 737-28A1212

ALERT ALERT
STEP TASK NAME IDENTIFICATION QTY MORE DATA

Remove the backing and

install the Decal and tape

on the P6-2 panel. Take

care not to contaminate

the adhesive and make

sure the tape has sufficient clearance to avoid

contact with the new relay

spacers and does not

overlap the relay cut-out.

(i)

DYMO 358 (3M

425 optional)

10 Apply Tape and Decal

The contact surfaces of

the relays, spacers, and

the panel, to remove contamination. (b)

11 Clean Surface - -

R18, R19, R20, R21,

R54, and R55. Refer to

SWPM 20-81-22 as an

accepted procedure for

installation of similar

LEACH relays.

S283A004-6 6

(LEACH P/N KCGX4L-001)

Fuel Pump Power

(GFI)

12 Install / New

Relay Spacer Kit 002-9667-001-000 6

For R146 and R147, and

related hardware, turned

180 degrees. Refer to

SWPM 20-81-22 as an

accepted procedure. (f)

Fuel Pump Power 10-60450-5 2

Relay Socket

13 Install / Kept

R146 and R147 in the

changed sockets. Refer

to SWPM 20-81-22 as an

accepted procedure for

installation of similar

LEACH relays. (g)

S283A004-1 2

(LEACH P/N

9524G-10674)

Fuel Pump Power

(GFI) Relay

14 Install / New

Between the flange of the

relay and the mounting

panel. (c)

0.0025 OHMS (2.5 8

MILLIOHMS)

15 Measure Resistance

On any bare metal

around the relays and

spacers. Refer to SOPM

20-41-02 as an accepted

procedure.

BMS 10-11, TYPE -

1

16 Apply Epoxy Primer

(a) Abrasive clean by Hand or with a rotary brush in accordance with APPENDIX A, Paragraph 2.a.

(b) Use Solvent to clean the contact surfaces in accordance with APPENDIX A, Paragraph 2.b.

FIGURE 7: P6-2 RELAY PANEL - FUEL PUMP POWER RELAY - REPLACEMENT

(SHEET 5 OF 6)

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ALERT ALERT
STEP TASK NAME IDENTIFICATION QTY MORE DATA

(c) Make sure that the resistance is 2.5 milliohms or less in accordance with APPENDIX A, Paragraph

5.b. If the resistance measurement is more than 0.0025 Ohms (2.5 milliohms), remove the relay, clean

the faying surfaces, install the relay and measure the bonding resistance again.

(d) Use the Fuel Pump Power (GFI) Relay, LEACH P/N 9524G-10674, as a template to mark the new

holes. Put the relay into the existing cutout, turned 180 degrees from its original position, then mark

and drill the new holes.

(e) It is not necessary to change the size or shape of the cut-out in the relay panel. The existing cut-out

is acceptable to allow installation of relay turned 180 degrees.

(f) Use the new holes for installation. The original holes are not used.

(g) Install the existing connectors for R146 and R147 turned 180 degrees to agree with the changed

sockets. Adjust wire bundles if necessary. Refer to SWPM 20-10-11 and SWPM 20-10-12, as accepted

procedures.

(h) Use Dymo M11 Tapewriter or equivalent to emboss the Decal. Use one, two or three pieces of tape,

as necessary, for the decal. Trim the tape and decal, as necessary, to fit the locations shown in Detail

A - AFTER.

(i) Install the decal at the approximate location shown.

FIGURE 7: P6-2 RELAY PANEL - FUEL PUMP POWER RELAY - REPLACEMENT

(SHEET 6 OF 6)

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ALERT ALERT
This Figure applies only to: Group 2-3, 6-7, 9-13, Configuration 1.

FIGURE 8: W0044 WIRE BUNDLE - LOCATION

(SHEET 1 OF 1)

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ALERT ALERT
This Figure applies only to: Group 2, Configuration 1.

Refer to 737-100/200 WDM 28-23-01 or 737-300/400/500 WDM 28-23-01 as applicable.

The flag note numbers shown below agree with the numbers shown in the flag symbols in the figure.

FIGURE 9: WIRE BUNDLE W0044 - WIRING CHANGES

(SHEET 1 OF 2)

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ALERT ALERT
FLAG NAME IDENTIFICATION QTY MORE DATA

NOTE

Use filler wire to build up diameter of wire

inside contact. Refer to SWPM 20-60-00

and SWPM 20-81-11 as accepted procedures.

1 Contact BACC47CP2T 12

Filler Wire 61-74479-2002 -

Use color white. Refer to SWPM 20-10-11

as an accepted procedure.

2 Lacing Tape 61-74479-2001 -

Imprinted "D1602 M/W R00020 AFT B/P

2". Install within 6 inches of connector.

Connector Identifi- 61-74479-10101 1

cation Tape

3

Imprinted "D1608 M/W R00054 CTR L

B/P". Install within 6 inches of connector.

Connector Identifi- 61-74478-10302 1

cation Tape

4

Imprinted "D1604 M/W R00021 FWD B/P

2". Install within 6 inches of connector.

Connector Identifi- 61-74479-10102 1

cation Tape

5

Imprinted "D1610 M/W R00019 FWD B/P

1". Install within 6 inches of connector.

Connector Identifi- 61-74479-10103 1

cation Tape

6

Imprinted "D1606 M/W R00055 CTR R

B/P". Install within 6 inches of connector.

Connector Identifi- 61-74478-10301 1

cation Tape

7

Imprinted "D1612 M/W R00018 AFT B/P

1". Install within 6 inches of connector.

Connector Identifi- 61-74479-10104 1

cation Tape

8

FIGURE 9: WIRE BUNDLE W0044 - WIRING CHANGES

(SHEET 2 OF 2)

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ALERT ALERT
This Figure applies only to: Group 3, 12, Configuration 1.

FIGURE 10: WIRE BUNDLE W0044 - WIRING CHANGES

(SHEET 1 OF 2)

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BOEING SERVICE BULLETIN 737-28A1212

ALERT ALERT
Refer to 737-100/200 WDM 28-23-01 and 737-100/200 WDM 28-23-02 or 737-300/400/500 WDM 28-23-01 and

737-300/400/500 WDM 28-23-02 as applicable.

The flag note numbers shown below agree with the numbers shown in the flag symbols in the figure.

FLAG NAME IDENTIFICATION QTY MORE DATA

NOTE

Use filler wire to build up diameter of

AWG 22 wire inside contact. Refer to

SWPM 20-60-00 and SWPM 20-81-11

as accepted procedures. (a)

1 Contact BACC47CP2T 1

Filler Wire 61-74479-2002 -

Use color white. Refer to SWPM 20-10-

11 as an accepted procedure.

2 Lacing Tape 61-74479-2001 -

Imprinted "D1602 M/W R00020 AFT B/P

2". Install within 6 inches of connector.

Connector Identifi- 61-74479-10101 1

cation Tape

3

Imprinted "D1608 M/W R00054 CTR L

B/P". Install within 6 inches of connector.

Connector Identifi- 61-74478-10302 1

cation Tape

4

Imprinted "D1604 M/W R00021 FWD B/P

2". Install within 6 inches of connector.

Connector Identifi- 61-74479-10102 1

cation Tape

5

Imprinted "D1610 M/W R00019 FWD B/P

1". Install within 6 inches of connector.

Connector Identifi- 61-74479-10103 1

cation Tape

6

Imprinted "D1606 M/W R00055 CTR R

B/P". Install within 6 inches of connector.

Connector Identifi- 61-74478-10301 1

cation Tape

7

Imprinted "D1612 M/W R00018 AFT B/P

1". Install within 6 inches of connector.

Connector Identifi- 61-74479-10104 1

cation Tape

8

Imprinted "D1818 M/W R00146 AFT AUX

FWD BOOST PUMP". Install within 6

inches of connector. (a)

Connector Identifi- 61-74478-10401 1

cation Tape

9

Imprinted "D1820 M/W R00147 AFT AUX

AFT BOOST PUMP". Install within 6

inches of connector. (a)

Connector Identifi- 61-74478-10402 1

cation Tape

10

(a) Airplanes in Group 12 have been delivered with wire provisions for Auxiliary Tanks installation.

If Auxiliary Tanks have been installed on these airplanes operators need to order this kit. If

Auxiliary Tanks have not been installed on these airplanes there are more parts than necessary

in this kit. Operators need to obtain only the necessary parts to incorporate this service bulletin

for Tank 1, Tank 2, and Center Tank.

FIGURE 10: WIRE BUNDLE W0044 - WIRING CHANGES

(SHEET 2 OF 2)

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ALERT ALERT
This Figure applies only to: Group 6-7, 9, Configuration 1.

Refer to 737-300/400/500 WDM 28-23-02.

The flag note numbers shown below agree with the numbers shown in the flag symbols in the figure.

FLAG NAME IDENTIFICATION QTY MORE DATA

NOTE

Use filler wire to build up diameter of

AWG 24 wire inside contact. Refer to

SWPM 20-60-00 and SWPM 20-81-11

as accepted procedures.

1 Contact BACC47CP2T 4

Filler Wire 61-74479-2002 -

Use color white. Refer to SWPM 20-10-

11 as an accepted procedure.

2 Lacing Tape 61-74479-2001 -

Imprinted "D1818 M/W R00146 AFT AUX

FWD BOOST PUMP". Install within 6

inches of connector.

Connector Identifi- 61-74478-10401 1

cation Tape

3

Imprinted "D1820 M/W R00147 AFT AUX

AFT BOOST PUMP". Install within 6

inches of connector.

Connector Identifi- 61-74478-10402 1

cation Tape

4

FIGURE 11: WIRE BUNDLE W0044 - WIRING CHANGES

(SHEET 1 OF 1)

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ALERT ALERT
This Figure applies only to: Group 10, Configuration 1.

Refer to 737-100/200 WDM 28-23-02.

The flag note numbers shown below agree with the numbers shown in the flag symbols in the figure.

FLAG NAME IDENTIFICATION QTY MORE DATA

NOTE

Use filler wire to build up diameter of AWG 22

wire inside contact. Refer to SWPM 20-60-00

and SWPM 20-81-11 as accepted procedures.

1 Contact BACC47CP2T 4

Filler Wire 61-74479-2002 -

Use color white. Refer to SWPM 20-10-11 as

an accepted procedure.

2 Lacing Tape 61-74479-2001 -

Imprinted "D1818 M/W R00146 AFT AUX FWD

BOOST PUMP". Install within 6 inches of connector.

Connector Identifi- 61-74478-10401 1

cation Tape

3

Imprinted "D1820 M/W R00147 AFT AUX AFT

BOOST PUMP". Install within 6 inches of connector.

Connector Identifi- 61-74478-10402 1

cation Tape

4

FIGURE 12: WIRE BUNDLE W0044 - WIRING CHANGES

(SHEET 1 OF 1)

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BOEING SERVICE BULLETIN 737-28A1212

ALERT ALERT
This Figure applies only to: Group 11, 13, Configuration 1.

FIGURE 13: WIRE BUNDLE W0044 - WIRING CHANGES

(SHEET 1 OF 2)

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BOEING SERVICE BULLETIN 737-28A1212

ALERT ALERT
Refer to 737-300/400/500 WDM 28-23-01 and 737-300/400/500 WDM 28-23-02.

The flag note numbers shown below agree with the numbers shown in the flag symbols in the figure.

FLAG NAME IDENTIFICATION QTY MORE DATA

NOTE

Use filler wire to build up diameter of AWG

22 and AWG 24 wire inside contact. Refer to

SWPM 20-60-00 and SWPM 20-81-11 as

accepted procedures. (a)

1 Contact BACC47CP2T 16

Filler Wire 61-74479-2002 -

Use color white. Refer to SWPM 20-10-11 as

an accepted procedure.

2 Lacing Tape 61-74479-2001 -

Imprinted "D1602 M/W R00020 AFT B/P 2".

Install within 6 inches of connector.

Connector Identifi- 61-74479-10101 1

cation Tape

3

Imprinted "D1608 M/W R00054 CTR L B/P".

Install within 6 inches of connector.

Connector Identifi- 61-74478-10302 1

cation Tape

4

Imprinted "D1604 M/W R00021 FWD B/P 2".

Install within 6 inches of connector.

Connector Identifi- 61-74479-10102 1

cation Tape

5

Imprinted "D1610 M/W R00019 FWD B/P 1".

Install within 6 inches of connector.

Connector Identifi- 61-74479-10103 1

cation Tape

6

Imprinted "D1606 M/W R00055 CTR R B/P".

Install within 6 inches of connector.

Connector Identifi- 61-74478-10301 1

cation Tape

7

Imprinted "D1612 M/W R00018 AFT B/P 1".

Install within 6 inches of connector.

Connector Identifi- 61-74479-10104 1

cation Tape

8

Imprinted "D1818 M/W R00146 AFT AUX

FWD BOOST PUMP". Install within 6 inches

of connector. (a)

Connector Identifi- 61-74478-10401 1

cation Tape

9

Imprinted "D1820 M/W R00147 AFT AUX AFT

BOOST PUMP". Install within 6 inches of

connector. (a)

Connector Identifi- 61-74478-10402 1

cation Tape

10

(a) Airplanes in Group 13 have been delivered with wire provisions for Auxiliary Tanks installation. If

Auxiliary Tanks have been installed on these airplanes operators need to order this kit. If Auxiliary

Tanks have not been installed on these airplanes there are more parts than necessary in this kit.

Operators need to obtain only the necessary parts to incorporate this service bulletin for Tank 1,

Tank 2, and Center Tank.

FIGURE 13: WIRE BUNDLE W0044 - WIRING CHANGES

(SHEET 2 OF 2)

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ALERT ALERT
This Figure applies only to: Group 8.

FIGURE 14: FUEL BOOST PUMP CONNECTOR - WIRE LOCATION

(SHEET 1 OF 1)

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ALERT ALERT
This Figure applies only to: Group 8.

FIGURE 15: FUEL BOOST PUMP GROUNDS - WIRE LOCATION

(SHEET 1 OF 1)

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ALERT ALERT
This Figure applies only to: Group 8.

FIGURE 16: FUEL BOOST PUMP CONNECTOR - WIRING CHANGES

(SHEET 1 OF 1)

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ALERT ALERT
This Figure applies only to: Group 8.

FIGURE 17: FUEL BOOST PUMP CONNECTOR - WIRE LOCATION

(SHEET 1 OF 1)

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ALERT ALERT
This Figure applies only to: Group 8.

FIGURE 18: FUEL BOOST PUMP GROUNDS - WIRE LOCATION

(SHEET 1 OF 1)

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ALERT ALERT
This Figure applies only to: Group 8.

FIGURE 19: FUEL BOOST PUMP CONNECTOR - WIRING CHANGES

(SHEET 1 OF 1)

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BOEING SERVICE BULLETIN 737-28A1212

ALERT ALERT
This Figure applies only to: Group 2-7, 9-13, Configuration 1.

FIGURE 20: FUEL BOOST PUMP CONTROL GROUND FAULT INTERRUPTER (GFI) CONTROL RELAY -

REFERENCE

(SHEET 1 OF 1)

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ALERT ALERT
This Figure applies only to: Group 1, 8.

FIGURE 21: WIRE BUNDLE W0044 - WIRING CHANGES

(SHEET 1 OF 1)

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BOEING SERVICE BULLETIN 737-28A1212

ALERT ALERT
This Figure applies only to: Group 2-4; Group 5, Configuration 1-2; Group 6, Configuration 1-2; Group

7, Configuration 1-2; Group 9, Configuration 1-2; Group 10-13.

FIGURE 22: P6-2 RELAY PANEL - GROUND STUDS AND BONDING JUMPER - INSTALLATION

(SHEET 1 OF 4)

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ALERT ALERT
FIGURE 22: P6-2 RELAY PANEL - GROUND STUDS AND BONDING JUMPER - INSTALLATION

(SHEET 2 OF 4)

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BOEING SERVICE BULLETIN 737-28A1212

ALERT ALERT
The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY

numbers shown below are the number of parts necessary for each airplane.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

In accordance with 737-100/200

SRM 51-30-02 or 737-300 SRM

51-40-05, or 737-400 SRM 51-

40-05, or 737-500 SRM 51-40-

05 as applicable. (a)

Remove/Dis- Rivet BACR15BB5D( ) 1

card

1

With 0.218-0.229 inch diameter

in accordance with 737-100/200

SRM 51-30-05 or 737-300 SRM

51-40-05, or 737-400 SRM 51-

40-05, or 737-500 SRM 51-40-

05 as applicable.

2 Drill Hole - 2

In accordance with 737-100/200

SRM 51-30-05 or 737-300 SRM

51-40-05, or 737-400 SRM 51-

40-05, or 737-500 SRM 51-40-

05 as applicable.

3 Deburr Hole - 2

Remove the paint on both side,

the panel area around the hole,

and the support angle around

the hole. (b)

4 Clean Surface - 4

On any bare metal around the

holes. Refer to SOPM 20-43-03

as an accepted procedure.

Chemical Conver- ALODINE -

sion Coating

5 Apply

FIGURE 22: P6-2 RELAY PANEL - GROUND STUDS AND BONDING JUMPER - INSTALLATION

(SHEET 3 OF 4)

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ALERT ALERT
STEP TASK NAME IDENTIFICATION QTY MORE DATA

To remove the contamination.

(c)

6 Clean Surface - 4

In accordance with APPENDIX

A, Paragraph 1.

7 Install (New) Bolt BACS12GU3K10 2

Install (New) Washer NAS1149D0316H 6

Install (New) Nut BACN10YR3CD 2

Install (New) Bonding Jumper BACJ40K5A5A6 1

To 35 to 40 Inch-Pound in accordance with APPENDIX A, Paragraph 1.

Torque Nut - 2

Between bonding jumper terminal lug and structure. Make sure

that the resistance is 0.001

Ohms (1.0 milliohms) or less.

(d)

0.001 OHMS (1.0 2

MILLIOHMS)

8 Measure Resistance

Between the relay mounting

panel and P6 Load Control

Center structure. Make sure that

the resistance is 0.0025 Ohms

(2.5 milliohms) or less. (d)

0.0025 OHMS (2.5 1

MILLIOHMS)

9 Measure Resistance

On any bare metal around the

ground studs. Refer to SOPM

20-41-02 as an accepted procedure.

BMS 10-11, TYPE -

1

10 Apply Epoxy Primer

(a) Operators that incorporated Boeing Service Bulletin 737-24-1145 have to use the "Optional" installation

of the ground studs in accordance with Detail C. Step 1 needs to be done only if the optional installation

is used.

(b) Abrasive clean by Hand or with a rotary brush in accordance with APPENDIX A, Paragraph 2.a.

(c) Use Solvent to clean the surface area around the holes in accordance with APPENDIX A, Paragraph

2.b.

(d) If the resistance measurement is greater than the maximum resistance shown, then disassemble parts,

clean faying surfaces, install parts and measure bonding resistance again. Refer to SWPM 20-20-00

as an accepted procedure.

FIGURE 22: P6-2 RELAY PANEL - GROUND STUDS AND BONDING JUMPER - INSTALLATION

(SHEET 4 OF 4)

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BOEING SERVICE BULLETIN 737-28A1212

ALERT ALERT
This Figure applies only to: Group 5, Configuration 2-3.

FIGURE 23: P6-2 RELAY PANEL - FUEL PUMP POWER GFI RELAY - TURN

(SHEET 1 OF 5)

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ALERT ALERT
FIGURE 23: P6-2 RELAY PANEL - FUEL PUMP POWER GFI RELAY - TURN

(SHEET 2 OF 5)

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ALERT ALERT
FIGURE 23: P6-2 RELAY PANEL - FUEL PUMP POWER GFI RELAY - TURN

(SHEET 3 OF 5)

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BOEING SERVICE BULLETIN 737-28A1212

ALERT ALERT
The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY

numbers shown below are the number of parts necessary for each airplane.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

S283A004-1 2 R18 and R19.

(LEACH P/N

9524G-10674)

Remove / Fuel Pump Power (GFI) Relay

Keep

1

For R18 and R19 and related hardware.Fuel Pump Power (GFI) Relay 10-60450-5 2

Socket

Remove /

Keep

Diameter 0.151 to 0.161

inch. (d) (e)

2 Drill Holes - 6

If necessary, remove the

paint around the relay

cutout, from the side of the

panel that will be in contact

with the relay. (a)

3 Clean Surface - -

If necessary, on the bare

surfaces. Refer to SOPM

20-43-03 as an accepted

procedure.

4 Apply Chemical Conversion Coating ALODINE -

Approximately as shown.

Use Dymo 358 Aluminium

tape or equivalent. (h)

5 Make Decal - 1

To prepare to install the

Decal and tape to cover

holes. Use TT-N-95 or

equivalent. Do not allow to

evaporate, but wipe dry

with a clean cloth.

6 Clean Surface - -

Remove the backing and

install the Decal and tape

on the P6-2 panel. Take

care not to contaminate

the adhesive and make

sure the tape has sufficient

clearance to avoid contact

with the new relay spacers

and does not overlap the

relay cut-out. (i)

DYMO 358 (3M 5

425 optional)

7 Install Tape and Decal

The contact surfaces of

the relays and the panel to

remove contamination. (b)

8 Clean Surface - -

FIGURE 23: P6-2 RELAY PANEL - FUEL PUMP POWER GFI RELAY - TURN

(SHEET 4 OF 5)

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BOEING SERVICE BULLETIN 737-28A1212

ALERT ALERT
STEP TASK NAME IDENTIFICATION QTY MORE DATA

For R18 and R19, and related hardware, in the

same location, but turned

180 degrees. Refer to

SWPM 20-81-22 as an accepted procedure. (f)

Fuel Pump Power (GFI) Relay 10-60450-5 2

Socket

Install /

Kept

9

R18 and R19 in the

changed sockets. Refer to

SWPM 20-81-22 as an accepted procedure for installation of similar LEACH relays. (g)

S283A004-1 2

(LEACH P/N

9524G-10674)

Install / Fuel Pump Power (GFI) Relay

Kept

Between the flanges of

R18 and R19 and the relay

mounting panel. (c)

0.0025 OHMS (2.5 2

MILLIOHMS)

10 Measure Resistance

If necessary, on any bare

metal around the relays.

Refer to SOPM 20-41-02

as an accepted procedure.

BMS 10-11, TYPE -

1

11 Apply Epoxy Primer

(a) Abrasive clean by Hand or with a rotary brush in accordance with APPENDIX A, Paragraph 2.a.

(b) Use Solvent to clean the contact surfaces in accordance with APPENDIX A, Paragraph 2.b.

(c) Make sure that the resistance is 2.5 milliohms or less in accordance with APPENDIX A, Paragraph 5.b.

If the resistance measurement is more than 0.0025 Ohms (2.5 milliohms), remove the relay, clean the

faying surfaces, install the relay and measure the bonding resistance again.

(d) Use the Fuel Pump Power (GFI) Relay, LEACH P/N 9524G-10674, as a template to mark the new holes.

Put the relay into the existing cutout, turned 180 degrees from its original position, then mark and drill

the new holes.

(e) It is not necessary to change the size or shape of the cut-out in the relay panel. The existing cut-out is

acceptable to allow installation of relay turned 180 degrees.

(f) Use the new holes for installation. The original holes are not used.

(g) Install the existing connectors for R18 and R19 turned 180 degrees to agree with the changed sockets.

Adjust wire bundles if necessary. Refer to SWPM 20-10-11 and SWPM 20-10-12, as accepted procedures.

(h) Use Dymo M11 Tapewriter or equivalent to emboss the Decal. Use one, two or three pieces of tape, as

necessary, for the decal. Trim the tape and decal, as necessary, to fit the locations shown in Detail A -

AFTER.

(i) Install the decal at the approximate location shown.

FIGURE 23: P6-2 RELAY PANEL - FUEL PUMP POWER GFI RELAY - TURN

(SHEET 5 OF 5)

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This Figure applies only to: Group 6, Configuration 2-3.

FIGURE 24: P6-2 RELAY PANEL - FUEL PUMP POWER GFI RELAY - TURN

(SHEET 1 OF 5)

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FIGURE 24: P6-2 RELAY PANEL - FUEL PUMP POWER GFI RELAY - TURN

(SHEET 2 OF 5)

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FIGURE 24: P6-2 RELAY PANEL - FUEL PUMP POWER GFI RELAY - TURN

(SHEET 3 OF 5)

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ALERT ALERT
The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY

numbers shown below are the number of parts necessary for each airplane.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

S283A004-1 2 R146 and R147.

(LEACH P/N

9524G-10674)

Remove / Fuel Pump Power (GFI) Relay

Keep

1

For R146 and R147 and

related hardware.

Fuel Pump Power (GFI) Relay 10-60450-5 2

Socket

Remove /

Keep

Diameter 0.151 to 0.161

inch. (d) (e)

2 Drill Hole - 6

If necessary, remove the

paint around the relay

cutout, from the side of the

panel that will be in contact

with the relay. (a)

3 Clean Surface - -

If necessary, on the bare

surfaces. Refer to SOPM

20-43-03 as an accepted

procedure.

4 Apply Chemical Conversion Coating ALODINE -

Approximately as shown.

Use Dymo 358 Aluminium

tape or equivalent. (h)

5 Make Decal - 1

To prepare to install the

Decal and tape to cover

holes. Use TT-N-95 or

equivalent. Do not allow to

evaporate, but wipe dry

with a clean cloth.

6 Clean Surface - -

Remove the backing and

install the Decal and tape

on the P6-2 panel. Take

care not to contaminate

the adhesive and make

sure the tape has sufficient

clearance to avoid contact

with the new relay spacers

and does not overlap the

relay cut-out. (i)

DYMO 358 (3M 5

425 optional)

7 Install Tape and Decal

The contact surfaces of

the relays and the panel to

remove contamination. (b)

8 Clean Surface - -

FIGURE 24: P6-2 RELAY PANEL - FUEL PUMP POWER GFI RELAY - TURN

(SHEET 4 OF 5)

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STEP TASK NAME IDENTIFICATION QTY MORE DATA

For R146 and R147, and

related hardware, in the

same location, but turned

180 degrees. Refer to

SWPM 20-81-22 as an accepted procedure. (f)

Fuel Pump Power (GFI) Relay 10-60450-5 1

Socket

Install /

Kept

9

R146 and R147 in the

changed sockets. Refer to

SWPM 20-81-22 as an accepted procedure for installation of similar LEACH relays. (g)

S283A004-1 2

(LEACH P/N

9524G-10674)

Install / Fuel Pump Power (GFI) Relay

Kept

Between the flange of

R146 and R147 and the

relay mounting panel. (c)

0.0025 OHMS (2.5 2

MILLIOHMS)

10 Measure Resistance

If necessary, on any bare

metal around the relays.

Refer to SOPM 20-41-02

as an accepted procedure.

BMS 10-11, TYPE -

1

11 Apply Epoxy Primer

(a) Abrasive clean by Hand or with a rotary brush in accordance with APPENDIX A, Paragraph 2.a.

(b) Use Solvent to clean the contact surfaces in accordance with APPENDIX A, Paragraph 2.b.

(c) Make sure that the resistance is 2.5 milliohms or less in accordance with APPENDIX A, Paragraph 5.b.

If the resistance measurement is more than 0.0025 Ohms (2.5 milliohms), remove the relay, clean the

faying surfaces, install the relay and measure the bonding resistance again.

(d) Use the Fuel Pump Power (GFI) Relay, LEACH P/N 9524G-10674, as a template to mark the new holes.

Put the relay into the existing cutout, turned 180 degrees from its original position, then mark and drill

the new holes.

(e) It is not necessary to change the size or shape of the cut-out in the relay panel. The existing cut-out is

acceptable to allow installation of relay turned 180 degrees.

(f) Use the new holes for installation. The original holes are not used.

(g) Install the existing connectors for R146 and R147 turned 180 degrees to agree with the changed sockets.

Adjust wire bundles if necessary. Refer to SWPM 20-10-11 and SWPM 20-10-12, as accepted procedures.

(h) Use Dymo M11 Tapewriter or equivalent to emboss the Decal. Use one, two or three pieces of tape, as

necessary, for the decal. Trim the tape and decal, as necessary, to fit the locations shown in Detail A -

AFTER.

(i) Install the decal at the approximate location shown.

FIGURE 24: P6-2 RELAY PANEL - FUEL PUMP POWER GFI RELAY - TURN

(SHEET 5 OF 5)

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ALERT ALERT
This Figure applies only to: Group 7, Configuration 2-3; Group 9, Configuration 2-3.

FIGURE 25: P6-2 RELAY PANEL - FUEL PUMP POWER GFI RELAY - TURN

(SHEET 1 OF 5)

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FIGURE 25: P6-2 RELAY PANEL - FUEL PUMP POWER GFI RELAY - TURN

(SHEET 2 OF 5)

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FIGURE 25: P6-2 RELAY PANEL - FUEL PUMP POWER GFI RELAY - TURN

(SHEET 3 OF 5)

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ALERT ALERT
The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY

numbers shown below are the number of parts necessary for each airplane.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

S283A004-1 2 R146 and R147.

(LEACH P/N

9524G-10674)

Remove / Fuel Pump Power (GFI) Relay

Keep

1

For R146 and R147 and

attaching hardware.

Fuel Pump Power (GFI) Relay 10-60450-5 2

Socket

Remove /

Keep

Diameter 0.151 to 0.161

inch. (d) (e)

2 Drill Holes - 6

If necessary, remove the

paint around the relay

cutout, from the side of the

panel that will be in contact

with the relay. (a)

3 Clean Surface - -

If necessary, on the bare

surfaces. Refer to SOPM

20-43-03 as an accepted

procedure.

4 Apply Chemical Conversion Coating ALODINE -

Approximately as shown.

Use Dymo 358 Aluminium

tape or equivalent. (h)

5 Make Decal - 1

To prepare to install the

Decal and tape to cover

holes. Use TT-N-95 or

equivalent. Do not allow to

evaporate, but wipe dry

with a clean cloth.

6 Clean Surface - -

Remove the backing and

install the Decal and tape

on the P6-2 panel. Take

care not to contaminate

the adhesive and make

sure the tape has sufficient

clearance to avoid contact

with the new relay spacers

and does not overlap the

relay cut-out. (i)

DYMO 358 (3M 5

425 optional)

7 Install Tape and Decal

The contact surfaces of

the relays and the panel to

remove contamination. (b)

8 Clean Surface - -

FIGURE 25: P6-2 RELAY PANEL - FUEL PUMP POWER GFI RELAY - TURN

(SHEET 4 OF 5)

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ALERT ALERT
STEP TASK NAME IDENTIFICATION QTY MORE DATA

For R146 and R147, and

related hardware, turned

180 degrees. Refer to

SWPM 20-81-22 as an accepted procedure. (f)

Fuel Pump Power (GFI) Relay 10-60450-5 2

Socket

Install /

Kept

9

R146 and R147 in the

changed sockets. Refer to

SWPM 20-81-22 as an accepted procedure for installation of similar LEACH relays. (g)

S283A004-1 2

(LEACH P/N

9524G-10674)

Install / Fuel Pump Power (GFI) Relay

Kept

Between the flanges of

R146 and R147 and the

relay mounting panel. (c)

0.0025 OHMS (2.5 2

MILLIOHMS)

10 Measure Resistance

If necessary, on any bare

metal around the relays.

Refer to SOPM 20-41-02

as an accepted procedure.

BMS 10-11, TYPE -

1

11 Apply Epoxy Primer

(a) Abrasive clean by Hand or with a rotary brush in accordance with APPENDIX A, Paragraph 2.a.

(b) Use Solvent to clean the contact surfaces in accordance with APPENDIX A, Paragraph 2.b.

(c) Make sure that the resistance is 2.5 milliohms or less in accordance with APPENDIX A, Paragraph 5.b.

If the resistance measurement is more than 0.0025 Ohms (2.5 milliohms), remove the relay, clean the

faying surfaces, install the relay and measure the bonding resistance again.

(d) Use the Fuel Pump Power (GFI) Relay, LEACH P/N 9524G-10674, as a template to mark the new holes.

Put the relay into the existing cutout, turned 180 degrees from its original position, then mark and drill

the new holes.

(e) It is not necessary to change the size or shape of the cut-out in the relay panel. The existing cut-out is

acceptable to allow installation of relay turned 180 degrees.

(f) Use the new holes for installation. The original holes are not used.

(g) Install the existing connectors for R146 and R147 turned 180 degrees to agree with the changed sockets.

Adjust wire bundles if necessary. Refer to SWPM 20-10-11 and SWPM 20-10-12, as accepted procedures.

(h) Use Dymo M11 Tapewriter or equivalent to emboss the Decal. Use one, two or three pieces of tape, as

necessary, for the decal. Trim the tape and decal, as necessary, to fit the locations shown in Detail A -

AFTER.

(i) Install the decal at the approximate location shown.

FIGURE 25: P6-2 RELAY PANEL - FUEL PUMP POWER GFI RELAY - TURN

(SHEET 5 OF 5)

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ALERT ALERT
NOTE: APPENDIX A contains electrical bonding data out of BAC5117-4 and BAC5117-6. Operators may use

the electrical bonding data in APPENDIX A or BAC5117-4 or BAC5117-6 as applicable.

1. DIRECT STANDARD GROUND STUD INSTALLATION

FIGURE1: DIRECT STANDARD GROUND STUD INSTALLATION

a. Surface Preparation

(1) Clean the structure surface in accordance with APPENDIX A, Paragraph 2.a. (CM1) and/or

Paragraph 2.b. (CM3).

(2) Clean a sufficient amount of the surface to ensure the entire area under the corrosion protective

washer 1 is clean.

(3) Clean the terminal or terminals in accordance with APPENDIX A, Paragraph 2.b. (CM3).

(4) Clean the corrosion protective washer 1 in accordance with APPENDIX A, Paragraph 2.b.

(CM3).

b. Direct Ground Stud Installation

(1) Install the direct ground stud and terminal or terminals.

(2) Torque the self-locking nut to 35-40 inch-pounds.

2. SURFACE PREPARATION AND CLEANING FOR ELECTRICAL BOND

a. Abrasive Clean by Hand (CM1) (Excerpts from; SWPM 20-20-00, 2.A. Cleaning Procedure 1 or

SOPM 20-11-03, 3.B. Cleaning Method CM1, (1) Hand Application of Abrasives)

Appendix A: ELECTRICAL BONDING

(SHEET 1 OF 6)

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ALERT ALERT
CAUTION: DO NOT USE THE ABRASIVE MATERIAL ON MATERIAL DIFFERENT FROM THE

TYPE ON WHICH IT WAS FIRST USED.

(1) Clean the specified surface by hand, using one of the following abrasive materials:

(a) Scotch - Brite Pad

(b) Garnet Sandpaper

(c) Wet/Dry Sandpaper

(2) Use a circular motion with the abrasive material.

(3) Continue until the coating is removed and the aluminum surface is bright. Remove a minimum

amount of aluminum.

(4) If the surface finish includes Corrosion Inhibiting Compound (CIC) applied on top of paint or

primer, remove the CIC a minimum of 0.10 inch beyond the area where the paint and primer

is removed. Use solvent cleaning method in accordance with APPENDIX A, Paragraph 2.b.

(CM3) to remove the CIC.

(5) Do not allow the cleaned bonding surface to be contaminated.

(6) Remove all temporary protective coatings or masking from a cleaned bonding surface just

prior to assembly of a bond.

(7) Clean the mating bonding surfaces again, in accordance with APPENDIX A, Paragraph 2.b.

(CM3).

b. Solvent Clean (CM3) (Excerpts from; SWPM 20-20-00, 2.E. Cleaning Procedure 5 or SOPM

20-11-03, 3.D. Cleaning Method CM3)

CAUTION: BE SURE TO USE A SOLVENT THAT AGREES WITH THE SURFACE TO BE

CLEANED.

(1) Solvent clean the surface.

(a) Use a solvent from this list:

1) Acetone

2) Ethyl alcohol, denatured

3) Isopropyl alcohol

4) Methyl Ethyl Ketone - sec-butyl alcohol, 1 - to - 1 mix

5) Methyl Propyl Ketone

6) Solvents with FB code in BAC5750

Appendix A: ELECTRICAL BONDING

(SHEET 2 OF 6)

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ALERT ALERT
(b) Solvents used for final cleaning shall be transferred from the original containers only to

new or dedicated clean containers using new or dedicated clean equipment.

(c) Dispense solvent onto a clean wiper, BMS15-5 Class A. Do not dip wiper into solvent

container.

(d) Rub the surface to be cleaned with solvent soaked wiper. Immediately wipe dry with a

clean, dry wiper. Do not allow solvent to evaporate to dryness. It may be necessary to

remove residue with a second dry wiper when using slow-evaporating solvents.

(e) Frequently exchange soiled wiper for a clean one.

(f) If unwanted matter stays, it could be because of fast solvent evaporation. Try to clean a

smaller area at one time.

(g) Repeat steps c. through e. until the wiper shows no soil.

3. TEST EQUIPMENT USED IN AREAS SUBJECT TO COMBUSTION, FIRE AND EXPLOSIONS

a. The test equipment to be used in Fire Hazard areas or Flammable leakage zones, must be approved

by Factory Mutual Approval Standard 3610 or qualified to Underwriters Laboratory (UL) Standard

913, for Class I, Group A, Atmosphere.

b. The following meters are approved for use in areas subject to combustion, fire, and explosions as

defined in UL Standard 913 for a Class I, Group A, Atmosphere:

(1) AVTRON Manufacturing Incorporated - Model T477W Bonding Meter.

(2) BCD Electronics Ltd. - Model M1 Bonding Meter, serial number A0000112 and on.

4. REQUIREMENTS

a. All designated bonds and all designated grounds must be tested to make sure that the resistance

requirements specified in the service bulletin are met. Sampling is not allowed.

b. Measure the resistance of designated bonds and designated grounds between the points specified

in the service bulletin.

c. Only certified personnel are allowed to make resistance measurements of designated bonds and

grounds.

5. TEST METHODS

a. GENERAL

WARNING: USE OF THE WRONG TEST EQUIPMENT MAY CAUSE FIRE OR EXPLOSION

(1) Choose test equipment for measuring resistance as follows:

Appendix A: ELECTRICAL BONDING

(SHEET 3 OF 6)

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ALERT ALERT
NOTE: Make sure that the meter to be used has a measuring range equal to or exceeding

the maximum allowable resistance for the measurement to be made.

(a) When measuring resistance in areas subject to combustion, fire and explosion, use only

the test equipment specified in accordance with APPENDIX A, Paragraph 3. Visually

check test equipment prior to taking it to areas subject to combustion, fire and explosion

and make sure that no physical damage has occurred which might have impaired the

vapor tightness of the instrument housing.

(2) All meters used for bonding resistance measurement must have a certified measuring range

equal to or exceeding the maximum allowable resistance for the measurement to be made.

(3) For meters which have range selectors, readings must be taken using the lowest range that

contains the measurement to be made.

(4) Impressions on electrical wire terminals caused by resistance measuring equipment that do

not expose the base metal are acceptable.

(5) Use the following conversion factors to convert from a meter reading displayed in milliohms

/ microhms to an equivalent value in ohms.

Ohms = Milliohms / 1,000

Ohms = Microhms / 1,000,000

(6) Do not use test equipment on circuits which have power applied.

b. RESISTANCE MEASUREMENT FROM THE GFI RELAY TO THE RELAY MOUNTING PANEL

Appendix A: ELECTRICAL BONDING

(SHEET 4 OF 6)

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ALERT ALERT
FIGURE2: RESISTANCE MEASUREMENT FROM THE GFI RELAY TO THE RELAY MOUNTING

PANEL

Appendix A: ELECTRICAL BONDING

(SHEET 5 OF 6)

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ALERT ALERT
(1) Select the applicable test equipment in accordance with APPENDIX A, Paragraph 3.

(2) Put one ohmmeter probe anywhere on the Relay and the other probe on the Mounting Panel,

0.25 Inch from the flange of the Relay or from the spacer, as applicable.

(3) If the Panel and/or the Relay is covered by a surface finish, remove a sufficient amount of the

surface finish to allow the probes to contact the structure bonding surface.

NOTE: Carefully pierce the surface finish with the probes to make contact with the structure

bonding surface.

(4) Make sure the resistance value shown on the ohmmeter is less than or equal to the resistance

requirement specified in the service bulletin.

(5) After testing is complete, re-apply chemical conversion coating to areas disturbed by the test

probes. Refer to SOPM 20-43-03 as an accepted procedure. For areas disturbed by the test

probes where the original finish included BMS 10-20 Type II, repair the chemical conversion

coating, then repair the BMS 10-20 Type II. Refer to SOPM 20-43-03 and SOPM 20-60-02

as accepted procedures.

Appendix A: ELECTRICAL BONDING

(SHEET 6 OF 6)

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ALERT ALERT